Ford Expedition 2008-2011

2011 Expedition, Navigator
Workshop Manual
Quick Links
Introduction
Master DTC Chart
Specifications
Metrics
Torque Wrench Adapter Formulas
Acronyms
Alphabetical Index
Table of Contents
1: General Information
00: Service Information
2: Chassis
04: Suspension
05: Driveline
06: Brake System
11: Steering System
3: Powertrain
03: Engine
07: Automatic Transmission
08: Manual Transmission, Clutch and Transfer Case
09: Exhaust System
10: Fuel System
4: Electrical
12: Climate Control System

13: Instrumentation and Warning Systems
14: Battery and Charging System
15: Audio Systems
17: Lighting
18: Electrical Distribution
19: Electronic Feature Group
5: Body and Paint
01: Body
02: Frame and Mounting

2011 Expedition, Navigator Workshop Manual
SECTION 100-00: Service Information 2011 Expedition, Navigator Workshop Manual

DESCRIPTION AND OPERATION Procedure revision date: 04/27/2012
Symbols Glossary
Symbols are used inside the graphics and in the text area to enhance the information.
Movement Symbols
Movement symbols provide detailed information to a required component movement. These component
movements can be rotational or 1-3 dimensional movements.
Item Description
1 Minor component movement clockwise/counterclockwise
2 Major component movement clockwise/counterclockwise
3 Component movement to the left/right/up/down
4 Component movement towards/away
5 3 dimensional component movement
6 2 dimensional component movement
7 3 dimensional component rotation
8 3 dimensional component cycling
Turn Symbols
Turn symbols are used to provide further information on the direction or angle of component turns.
Symbols Glossary 1
Item Description
1 Turn the component clockwise through 45
2 Turn the component counterclockwise through 45
7 Turn the component clockwise through 2 complete turns
8 Turn the component counterclockwise through 2 complete turns
Steering Wheel Symbols
Steering wheel symbols are used to provide further information to a required steering wheel position or
steering column lock status.
Symbols Glossary 2
Item Description
1 Steering wheel in straight ahead position
2 Steering column lock locked
3 Steering column lock unlocked
4 Turn the steering wheel to the 90 left position
5 Turn the steering wheel to the 90 right position
6 Turn the steering wheel to the left-hand end position
7 Turn the steering wheel to the right-hand end position
Body Types
Body type symbols are used to identify different body configurations.
Symbols Glossary 3
Item Description
1 3, 4, 5-door body style
2 Wagon body style
3 Sport utility vehicle body style
4 Coupe body style
5 Convertible body style
6 Van body style
7 3, 4, 5-door body style - Top View
8 Wagon body style - Top View
9 Underbody view
10 Right-hand drive (RHD) vehicle
11 Left-hand drive (LHD) vehicle
Gearshift lever and selector lever position symbols
Gearshift lever and selector lever position symbols are used to show the lever position that is required to be
selected to carry out a procedure step.
Symbols Glossary 4
Item Description
1 Replaced by symbol 9
9 Set the selector lever to the park (P) position
10 Set the selector lever to the reverse ( R ) position
11 Set the selector lever to the neutral (N) position
12 Set the selector lever to the drive (D) position
13 Set the selector lever to the drive (S) position
14 Set the selector lever to the drive (M) position
15 Set the selector lever to the drive (-) position
16 Set the selector lever to the drive (+) position
17 Set the gearshift lever to the neutral (N) position
18 Further gearshift lever positions that may appear in Illustrations
Screwdriver symbols
Symbols Glossary 5
The screwdriver symbols are used to show which screwdriver bit is recommended to carry out a procedure
step.
Item Description
1 Screwdriver
2 Cross bladed screwdriver
3 Flat-bladed screwdriver
4 Hexagonal screwdriver
5 TORX screwdriver
Pliers Symbols
The plier symbols are used to show which pliers is recommended to carry out a procedure step.
Symbols Glossary 6
Item Description
1 Combination pliers
2 Side cutter pliers
3 Securing ring - inner
4 Securing ring - outer
5 Hose clamp pliers
6 Locking pliers
7 Long nose pliers
Drill Symbols
The drill symbols are used to show which type and size of drill bit is recommended to carry out a procedure
step.
Symbols Glossary 7
Item Description
1 Drill bit with a specified diameter
2 Hole saw with a specified diameter
3 Stepped drill bit with a specified diameter
4 Tap with a specified diameter
5 Die with a specified diameter
6 Scraper for circular holes
7 Scraper for straight edges
Cutting Tool Symbols
The cutting tool symbols are used to show which type of cutting tool is recommended to carry out a procedure
step.
Symbols Glossary 8
Item Description
1 Cutting knife
2 Air body saw
3 Scissors
4 Grinder
5 Jig saw
6 Plasma cutter
7 Sanding Paper
8 Wire brush
Apply Chemical or load symbols
The apply chemical or load symbols are used to show where to apply which type of chemical or load to carry
out a procedure step.
Symbols Glossary 9
Item Description
1 Apply the substance from the specified tube
2 Apply the substance from the specified cartridge
3 Apply the specified chemical with a brush
4 Apply the specified load to the specified component
5 Apply a bead with a specific diameter from the specified tube
6 Apply a bead with a specific diameter from the specified cartridge
7 Apply the specified chemical with a roller
8 Apply hot glue to the specified component
9 Apply the specified amount of fluid from the fluid can
10 Apply fluid from the fluid can
11 Clean the specified component with the specified material
12 Apply a broken bead from the specified tube
13 Apply the specified chemical from a spray can
14 Apply the specified lubricant to the specified component
15 Apply spot welds to the specified component
16 Apply a continuous weld to the specified component
17 Handle the fluid using a syringe
18 Extract the specified amount of fluid using a syringe
Measurement Symbols
Symbols Glossary 10
The measurement symbols are used to show where to measure which type of measurement to carry out a
procedure step.
Item Description
1 Measure the current using a digital multimeter
2 Measure the voltage using a digital multimeter
3 Measure the resistance using a digital multimeter
4 Measure the length/distance
5 Check that the specified pressure is available using a suitable pressure gauge
6 Measure the pressure at the specified port using a suitable pressure gauge
7 Measure the time using a suitable stopwatch
8 Wait for the specified period of time
9 The specified task requires the specified minimum temperature
10 The specified task requires the specified maximum temperature not to be exceeded
11 The specified task requires the specified temperature range
12 The specified task requires the specified temperature
13 Measure and check for the specified value using a dial indicator gauge
14 Measure and check for the specified MAX value using a dial indicator gauge
15 Measure and check for the specified MIN value using a dial indicator gauge
General equipment symbols
Symbols Glossary 11
The general equipment symbols are used to show where to use which type of general equipment to carry out a
procedure step.
Item Description
1 Hot air gun
2 Soldering iron
3 Scraper
4 Scriber
5 Securing strap
6 File with specified size
7 Center punch
8 Marker
9 Mallet
10 Hose clamp
11 Interior trim remover
12 Vacuum cleaner
13 Strap wrench
14 Wedge
15 Pin punch
16 Air blow gun
17 Relocate and support the component
Symbols Glossary 12
Welding Symbols
These symbols indicate the type of welding to be used.
Item Description
1 Metal inert gas (MIG) / Metal active gas (MAG) welding equipment
2 Metal inert gas (MIG) welding equipment
3 Metal inert gas (MIG) brazing equipment
4 Apply a continuous weld to the specified component
5 Apply spot welds to the specified component
6 C-clamp
Drilling and grinding symbols
These symbols indicate the type of drilling or grinding to be used.
Symbols Glossary 13
Item Description
1 Drill through first body layer with a suitable diameter
2 Drill through first body layer with the specified diameter
3 Drill through the indicated number of body layers with a suitable diameter
4 Drill through the indicated number of body layers with the specified diameter
5 Drill through the indicated number of body layers with a suitable diameter
6 Drill through the indicated number of body layers with the specified diameter
7 Drill through all body layers with a suitable diameter
8 Drill through all body layers with the specified diameter
9 Grind one layer
10 Grind two layers
11 Grind to last layer
12 Grind all layers
13 Material thickness > Xmm
Material Symbols
The material symbols are used to show where to use which type of material to carry out a procedure step.
Symbols Glossary 14
Item Description
1 Remove/Install the specified blind rivet
2 Apply tape to the specified component/area
3 Remove/Install the specified cable tie
Miscellaneous Symbols
These symbols provide further information that is required to carry out a procedure step.
Item Description
Symbols Glossary 15
1 Set the ignition switch to the 0 position

2 Set the ignition switch to the II position
3 The procedure step requires the aid of the specified number of supporting technicians
4 Self contained breathing apparatus
5 General prohibition used in combination with another symbol
6 Do not use power tools
7 Visual check
8 Noise check
9 Dispose the specified component
10 Replaced by item 9 (Dispose the specified component)
11 Set the engine speed to the specified value
12 Fully apply the parking brake lever
13 Fully release the parking brake lever
14 Do not dispose of batteries into the waste bin
15 Visual check using a mirror
16 Area/component must be dry
Mandatory Protective Equipment - Health and safety symbols
The protective equipment symbols advise to use a mandatory protective equipment to avoid or at least reduce
possible health and safety risks.
Item Description
1 Wear protective gloves
2 Wear face guard
3 Wear safety goggles
Symbols Glossary 16
4 Wear ear protectors

5 Wear safety goggles and ear protectors
6 Wear a respirator
Prohibition - Health and safety symbols and component damage
The prohibition symbols are used to prohibit the specified actions to avoid or at least reduce possible
component damage and health and safety risks.
Item Description
1 General Prohibition symbol
2 No naked flames
3 No smoking
4 No water
5 Do not touch
6 Do not switch
7 No grinding
Warning Symbols - Health and Safety Warnings and Component damage
The warning symbols are used to advise on hazardous conditions to avoid or at least reduce possible
component damage and health and safety risks.
Symbols Glossary 17
Item Description
1 Hazardous voltage/Electrical shock/Electrocution
2 Fire hazard/Highly flammable
3 Burn hazard/Hot surface
4 Automatic start-up
5 Toxic
6 Explosive material
7 Battery hazard
8 Corrosive material
9 Lifting hazard
10 Hand crush/Force from above
11 Cutting of fingers or hand
12 Pressure hazard
13 Invisible laser radiation. Do not view directly with optical instruments (magnifiers). Class 1M laser
product
Control Diagram symbols - Description and Operation procedures
These symbols provide further information on the type of connectivity, direction of flow or type of data bus of
a system.
Symbols Glossary 18
Item Description
1 Medium Speed Controller Area Network
2 High Speed Controller Area Network
3 Local Interconnect Network
4 Wires cross but are not connected
Symbols Glossary 19
Symbols Glossary 20

Using This Manual
Introduction
This manual describes and directs repair procedures for this vehicle model year. It includes diagnostics for all
vehicle systems except driveability and emission control. Refer to the separate Powertrain Control/Emissions
Diagnosis (PC/ED) manual for driveability and emission control diagnostics.
Information is organized into groups, with sections that have subsections dividing them.
Warnings, Notices, and Notes in This Manual
Warnings provide information to avoid personal injury and to make sure service actions on critical safety
systems are performed correctly.
Notices provide information to avoid damage to the vehicle or a component.
Notes provide information critical for a complete and effective repair.
Warnings that apply to an entire system or workshop manual section are located in section 100-00 Description
and Operation Safety Warnings .
Warnings, Notices, or Notes that apply to an entire procedure will be placed at the beginning of the procedure.
Warnings, Notices, or Notes that apply to a single step are placed at the beginning of the step. Those that
apply to a group of steps will be placed at the first step requiring it.
Vehicle and Engine Orientation Identifiers
LH and RH vehicle designations are oriented from the driver's seat position looking forward. LH and RH
engine designations are oriented from the flywheel position looking towards the crankshaft pulley.
How to Use Diagnostic Information
DTC and Symptom Charts
Module DTC Charts are used to begin and direct the diagnosis of a DTC. Symptom Charts contain concern
symptoms and direct solutions either in the chart or in a linked Diagnostic Routine. Both DTC and Symptom
Charts may provide the solution within the chart, or provide a link to the appropriate Diagnostic Routine.
In some sections, the Symptom Chart is preceded by a Preliminary Inspection which must be followed prior to
using the Symptom Chart
Using Module DTC Charts
This Workshop Manual contains diagnostics for DTCs set by vehicle modules. Driveability and emission
DTCs are covered in the separate Powertrain Control/Emissions Diagnosis (PC/ED) manual. If a PCM-set
DTC is not listed in the Workshop Manual, it is serviced in the Powertrain Control/Emissions Diagnosis
(PC/ED) manual.
DTC diagnostics are found in both on-line and printed publications and are used as follows:
Using This Manual 21

On-line publications: Using the left side menu, click on the Master DTC Chart link to view the
vehicle module DTC charts. Each module has a chart with links or in-chart solutions for all DTCs
diagnosed in the Workshop Manual.
Printed publications: Use the DTC index in the rear of the book.
Diagnostic Methods
Diagnostic Methods provides information to support diagnosing Ford vehicles. Diagnostic strategies,
diagnostic tool support information, and advanced circuit testing methods are included. REFER to Diagnostic
Methods .
Diagnostic Routines
Diagnostic Routines provide information to determine the root cause of concerns addressed in either a DTC
Chart or Symptom Chart. Each Diagnostic Routine contains:
Diagnostic Overview
Wiring Diagram References (as applicable)
Normal Operation and Fault Conditions
Visual Inspection and Diagnostic Pre-checks
Tool Table (as applicable)
Material Table (as applicable)
Pinpoint Test Steps
Component Tests
Component Tests are used to separately analyze a single common component in a system. The test will
determine if the part is functioning correctly.
Mechanical Procedures Such As Removal and Installation
Reuse Of Fasteners, Seals, Or Gaskets
The following is a list of assumptions made in the reuse of fasteners, seals, or gaskets.
Seals and gaskets must be replaced unless otherwise specified.

Standard fasteners are reused unless otherwise specified.
Fasteners with self-locking features must be replaced unless otherwise noted. Reminder text may or
may not be included with the procedure step. Examples of fastener coatings or fasteners with
mechanical locking (with the locking features highlighted yellow) are shown in illustration 1.
Torque to yield bolts (bolts with more than one stage of tightening torque and a final torque angle
specification) must be discarded and new torque to yield bolts installed unless otherwise stated within
the procedure.
Illustration 1 - self-locking coatings or locking feature are highlighted yellow
Graphics
Illustration 1 - self-locking coatings or locking feature are highlighted yellow 22

Illustrations in this manual may be used to replace written step instructions. Color-coding (see color scheme in
this document) is used to communicate the required step action or actions. Service action icons (see Symbols
Glossary ) are used to add additional information regarding the required action.
The color scheme in a step graphic (an illustration used in removal or installation steps) indicates
servicing information as follows:
Fasteners (including panel retainers) or electrical connectors - Magenta (Purple)
Target component that is to be removed - Blue
Components that must be removed prior to the target component shown in blue - Brown or
Green
Components placed aside for access, but not removed; highlighted areas such as inspection
areas, adjustments or measurements - Yellow
Essential Special Service Tools (ESSTs) and other tools - Pale Blue
Chemical or Sealer apply areas - Alternating blue and white dashes (see illustration 4)
Sectioned or cut-away areas - Red
Remaining components - Grey
Callouts in graphics indicate removal (or tightening) order, or identify individual instructions in substeps of
the same number (such as different torque values).
Arrows containing x numbers (Illustration 2) indicate the number of identical fasteners or connectors to be
removed or installed in the graphic.
In Illustration 2, two identical fasteners are indicated by the x2 arrow, with another arrow illustrating a third
fastener of a different type. Because the different fasteners require different torques, callouts are used to
identify those two torque values in the associated step text. The hose clamp is another fastener to be removed.
The yellow coloring of the hose indicates it is to be moved aside (not removed).
The following written steps would be necessary if the illustration did not have color coding:
1. Remove the engine oil pipe fastener at the engine connection.
2. Remove the two engine oil pipe fasteners from the turbocharger and remove the pipe.
3. Remove the air inlet hose from the turbocharger and position aside.
Illustration 2
Hidden fasteners, such as panel retainers, are identified in the illustration by a magenta disc. An inset detail
view illustrating the fastener type may be included (Illustration 3).
Illustration 2 23
Illustration 3 - Note motion arrow at panel bottom; it indicates to lift panel up, then move inward to remove
Symbols
Symbols may be used inside graphics or in the text area to communicate service actions. The following
examples demonstrate the use of some of these symbols. REFER to Symbols Glossary for a complete symbols
list with explanations.
In the Illustration 4 example, service action symbols are shown as used to direct the application of sealer,
lubricant, weight, tape or cleaning detergent to a component. In this example a bead diameter of "xx"
millimeters is prescribed. The blue and white dashes indicate where the material is applied.
Illustration 4
Illustration 5 is an example of location symbols used to show the location of a component tem within the
vehicle.
Illustration 5
Illustration 6 shows how gearshift lever or selector lever position symbols may be used to indicate the
gearshift lever or selector lever position required. The required Essential Special Service Tool to align the
shift mechanism is shown in pale blue and identified by ESST number.
Illustration 6
Illustration 3 - Note motion arrow at panel bottom; it indicates to lift panel up, then move inward to 24
remove
Callouts or arrows may be used to identify components for supporting special information, such as a required
sequence or to indicate a number of identical components. Illustration 7 shows a removal order in the top
graphic and the bottom graphic indicates 12 identical bolts.
Illustration 7
Standard tool symbols direct the use of standard tools to perform a service action, such as the cutting of carpet
shown in Illustration 8. Tool symbols may include dimensional values (for example, a drill with a specified
diameter).
Illustration 8
Illustration 6 25
Illustration 8 26

Safety Warnings
Review carefully the General Service Health and Safety Precautions below before beginning any repair.
Following these general service warnings are specific system warnings that must be carefully reviewed before
beginning work on any listed system.
General Service Health and Safety Precautions
WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this instruction
may result in serious personal injury.
WARNING: Wear protective gloves when handling components or parts that have pointed or sharp
edges. Failure to follow this instruction may result in serious personal injury.
WARNING: Do not work under the hood of a vehicle with a damaged cooling fan, as it can separate
during operation. With the ignition OFF, inspect all cooling fans for damage, cracks or separation and
replace with a new fan as necessary. Failure to follow this instruction may result in serious personal
injury.
WARNING: Vehicles with engine auto start-stop technology may start automatically with the
ignition on. Make sure the ignition is off when servicing or working in close proximity to rotating
engine parts. Failure to follow this instruction may result in serious personal injury.
WARNING: Before raising the vehicle on a hoist, make sure the hoist capacity is adequate for the
vehicle weight, including any vehicle cargo or modifications. Always position the hoist lift arms as
shown in the illustration. Do not use the engine to power the drive wheels unless all drive wheels are
elevated off the ground. Incorrect hoist arm positioning or drive wheels in contact with the ground can
cause unintended vehicle movement. Failure to follow these instructions may result in serious personal
injury or death.
WARNING: Before lifting the vehicle with a jack, make sure the jack capacity is adequate for the
vehicle weight, including any vehicle cargo or modifications. Identify the correct jacking points as
shown in the illustration. Position the vehicle on a hard, level surface. After jacking, always support
vehicle with jack stands. Never get under a vehicle supported only by a jack. Set the parking brake and
block all wheels remaining on the ground. Failure to follow these instructions may result in unintended
vehicle movement and serious personal injury or death.
WARNING: Turn off (disable) the power running boards (if equipped) before jacking, lifting or
placing any object under the vehicle. Never place your hand between the power running board and the
vehicle. Extended power running boards will retract when doors are closed. Failure to follow these
instructions may result in serious personal injury.
WARNING: Never support an engine by the intake or exhaust manifolds. The engine may drop
suddenly. Failure to follow this instruction may result in serious personal injury.
WARNING: Disconnect the window regulator motor connector before working inside the vehicle
doors. Service actions inside the door (such as door latch, handle or lock cylinder service) or operating
the remote keyless entry (RKE) fob may activate the windows on vehicles equipped with global
open/close. Serious injury to hands or arms may occur if a window motor is activated during service.
Failure to follow these instructions may result in serious personal injury.
Safety Warnings 27
WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock absorber
and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction may
result in serious personal injury.
WARNING: Keep solvents away from ignition sources. Solvents may be flammable and can ignite or
explode if not handled correctly. Failure to follow this instruction may result in serious personal injury.
WARNING: Use only a type-D fire extinguisher to extinguish magnesium fires. Never attempt to use
a type-A, -B, -C extinguisher, or water, as these items are ineffective and may accelerate a magnesium
fire. Failure to follow these instructions may result in serious personal injury.
WARNING: Always secure transmission, transfer case, and axle assemblies to their service jack.
Avoid obstructions while lowering and raising the jack. Improperly secured assemblies or contact with
obstructions may cause the assembly to fall off the jack, which could result in serious personal injury.
WARNING: Always verify that the lockpin on a bench-mounted holding fixture is correctly secured
to help prevent unexpected component rotation. Failure to follow this instruction may result in serious
personal injury.
WARNING: Carefully read cautionary information on product label. For emergency medical
information seek medical advice. In the USA or Canada on Ford/Motorcraft products call:
1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if
available. Failure to follow these instructions may result in serious personal injury.
WARNING: Use tools, not fingers, to hold flagnuts. Flagnuts may slip or spin unexpectedly when
removing fasteners. Failure to follow this instruction may result in injured fingers.
Carefully review the following system safety warnings before beginning any service or repair work.
High Voltage System Health and Safety Precautions
WARNING: To prevent the risk of high-voltage shock, always follow precisely all warnings and
service instructions, including instructions to depower the system. The high-voltage system utilizes
approximately 300 volts DC, provided through high-voltage cables to its components and modules. The
high-voltage cables and wiring are identified by orange harness tape or orange wire covering. All
high-voltage components are marked with high-voltage warning labels with a high-voltage symbol.
Failure to follow these instructions may result in serious personal injury or death.
WARNING: Never install the service disconnect plug when a high-voltage service cover is removed.
Always install the cover prior to connecting the service disconnect plug. The cover prevents inadvertent
contact with the high voltage which is present at several points under the cover. Failure to follow these
instructions may result in serious personal injury or death.
WARNING: Turn OFF the ignition switch for a minimum of 5 minutes before removing
high-voltage cables. High-voltage cables and wiring are orange in color. The nominal high-voltage
traction battery voltage (HVTB) is 330 V DC. Failure to follow these instructions may result in serious
personal injury or death.
Climate Control System Health and Safety Precautions
WARNING: Air conditioning R-134a liquid refrigerant is capable of harming eyes or freezing skin.
Always wear safety goggles and avoid contact with liquid refrigerant. Failure to follow these
Safety Warnings 28
WARNING: Air conditioning R-134a refrigerant gas is capable of displacing the air necessary for
breathing in a confined space and can produce toxic gasses if burned at high temperatures. Do not
release a large quantity of R-134a gas within a confined space or allow it to be exposed to a high
temperature flame (such as a torch). Consult the Material Safety Data Sheet for further information.
Failure to follow these instructions may result in serious personal injury or death.
WARNING: Use extreme care and observe all safety and service precautions related to the use of
refrigerants as outlined on refrigerant tank and on recovery and charging equipment. Failure to follow
these instructions may result in serious personal injury.
WARNING: Before disconnecting any heater water hoses, shut OFF the engine and wait until
engine is fully cool. Failure to comply with this warning may result in serious injury or burns from hot
liquid escaping from the engine cooling system.
WARNING: The electric booster heater may become hot during use and can burn unprotected skin.
Allow enough time for the heater to cool before servicing. Failure to follow this instruction may result
in serious personal injury.
Battery and Battery Charging System Health and Safety Precautions
WARNING: Batteries contain sulfuric acid and produce explosive gases. Work in a well-ventilated
area. Do not allow the battery to come in contact with flames, sparks or burning substances. Avoid
contact with skin, eyes or clothing. Shield eyes when working near the battery to protect against
possible splashing of acid solution. In case of acid contact with skin or eyes, flush immediately with
water for a minimum of 15 minutes, then get prompt medical attention. If acid is swallowed, call a
physician immediately. Failure to follow these instructions may result in serious personal injury.
WARNING: Always lift a plastic-cased battery with a battery carrier or with hands on opposite
corners. Excessive pressure on the battery end walls may cause acid to flow through the vent caps,
resulting in personal injury and/or damage to the vehicle or battery.
WARNING: Battery posts, terminals and related accessories contain lead and lead components.
Wash hands after handling. Failure to follow these instructions may result in serious personal injury.
Brake System Health and Safety Precautions
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.
Additionally, do not use brake fluid that has been previously drained. Following these instructions will
help prevent system contamination, brake component damage and the risk of serious personal injury.
WARNING: Do not breathe dust or use compressed air to blow dust from storage containers or
friction components. Remove dust using government-approved techniques. Friction component dust
may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if
dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure
may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or
may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure
to follow these instructions may result in serious personal injury.
Body Repair Health and Safety and General Precautions
Safety Warnings 29
WARNING: Always refer to Material Safety Data Sheet (MSDS) when handling chemicals and wear
protective equipment as directed. Examples may include but are not limited to respirators and
chemically resistant gloves. Failure to follow these instructions may result in serious personal injury.
WARNING: Always wear protective equipment including eye protection with side shields, and a
dust mask when sanding or grinding. Failure to follow these instructions may result in serious personal
injury.
WARNING: Do not carry out body side sectioning repairs in areas of door hinge or striker
anchoring points. Welding within 50 mm (1.96 in) of door hinge or striker locations may compromise
structural integrity during a collision. Failure to follow these instructions may result in serious injury to
vehicle occupant(s).
WARNING: Invisible ultraviolet and infrared rays emitted in welding can injure unprotected eyes
and skin. Always use protection such as a welder's helmet with dark-colored filter lenses of the correct
density. Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest
shade providing adequate visibility are recommended. It is strongly recommended that persons
working in the weld area wear flash safety goggles. Also wear protective clothing. Failure to follow
WARNING: All safety belt components must be inspected and corrected as part of any collision
repair. Inspect all safety belt components as prescribed by Safety Belt Inspection and Repair After a
Collision found in Section 501-20A General Procedures of this manual. Failure to follow this instruction
may result in incorrect operation of the safety belt system and increase the risk of serious personal
injury or death in a crash.
WARNING: If a vehicle has been in a crash, inspect the restraints control module (RCM) and the
impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting areas to
the original production configuration. A new RCM and sensors must be installed whether or not the air
bags have deployed. Failure to follow these instructions may result in serious personal injury or death
in a crash.
Engine Cooling System Health and Safety Precautions
WARNING: Always allow the engine to cool before opening the cooling system. Do not unscrew the
coolant pressure relief cap when the engine is operating or the cooling system is hot. The cooling system
is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly.
Gasoline and Gasoline-Ethanol Fuel System Health and Safety Precautions
WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components,
relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains
under high pressure, even when the engine is not running. Failure to follow this instruction may result
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working
on or near any fuel-related component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: Clean all fuel residue from the engine compartment. If not removed, fuel residue may
ignite when the engine is returned to operation. Failure to follow this instruction may result in serious
Safety Warnings 30
personal injury.
WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio
equipment of any type when working on or near any fuel-related component. Highly flammable
mixtures are always present and may be ignited. Failure to follow these instructions may result in
serious personal injury.
WARNING: Always disconnect the battery ground cable at the battery when working on an
evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are always
present and may be ignited. Failure to follow these instructions may result in serious personal injury.
WARNING: When handling fuel, always observe fuel handling precautions and be prepared in the
event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition sources.
WARNING: Remove the fuel filler cap slowly. The fuel system may be under pressure. If the fuel
filler cap is venting vapor or if you hear a hissing sound, wait until it stops before completely removing
the fuel filler cap. Otherwise, fuel may spray out. Failure to follow these instructions may result in
WARNING: Avoid contact with fuel during a visual inspection for fuel leaks with the engine
running. Do not work on the fuel system until the pressure has been released and the engine has cooled.
Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel may cause
cuts and contact with hot fuel may cause burns. Failure to follow these instructions may result in
Diesel Fuel System Health and Safety Precautions
WARNING: Contact with exposed fuel injector wiring, if energized, may result in electric shock.
Use care when working on or around energized fuel injector wiring. Fuel injector wiring supplies high
voltage to operate the fuel injectors. Failure to follow this instruction may result in serious personal
injury.
WARNING: Do not work on the fuel system until the pressure has been released and the engine has
cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel
may cause cuts and contact with hot fuel may cause burns. Failure to follow these instructions may
Safety Belt and Supplemental Restraint System (SRS) Health and Safety Precautions
WARNING: Always carry or place a live air bag module with the air bag and deployment door/trim
cover/tear seam pointed away from the body. Do not set a live air bag module down with the
deployment door/trim cover/tear seam face down. Failure to follow these instructions may result in
serious personal injury in the event of an accidental deployment.
WARNING: Deploy all supplemental restraint system (SRS) devices (air bags, pretensioners, load
limiters, etc.) outdoors with all personnel at least 9 meters (30 feet) away to make sure of personal
safety. Due to the loud report which occurs when an SRS device is deployed, hearing protection is
required. Failure to follow these instructions may result in serious personal injury.
WARNING: Do not bleach or re-dye the safety belt webbing, as the webbing may weaken. Failure to
follow this instruction may increase the risk of serious personal injury or death in a crash.
Safety Warnings 31
in a crash.
WARNING: All safety belt components must be inspected and corrected as part of any collision
repair. Inspect all safety belt components as prescribed by Safety Belt Inspection and Repair After a
Collision found in Section 501-20A General Procedures of this manual. Failure to follow this instruction
may result in incorrect operation of the safety belt system and increase the risk of serious personal
WARNING: Anytime the Safety Canopy or side air curtain module has deployed, a new headliner
and new A-, B-, C-, and/or D-pillar upper trim panels and attaching hardware must be installed. Make
sure the headliner includes the word AIRBAG where it meets each B-pillar trim panel. Remove any
other damaged components/hardware, and install new components/hardware as required. Always use
new torque-prevailing type J-nuts when installing the Safety Canopy. Failure to follow these
instructions may result in the Safety Canopy or side air curtain module deploying incorrectly and
increases the risk of serious personal injury or death in a crash.
WARNING: Do not repair or service restraint component connector terminals. If restraint

connector terminals need repair, replace with the service connector pigtails. Failure to follow this
instruction may result in incorrect operation of the vehicle safety restraint, which increases the risk of
serious personal injury or death in a crash.
WARNING: Never disassemble or tamper with seat belt deployable components, including
pretensioners, load limiters and inflators. Never back probe deployable device electrical connectors.
Tampering or back probing may cause an accidental deployment and result in personal injury or
death.
WARNING: Never tamper with, repair, or modify a Restraints Control Module (RCM) or any other
Supplemental Restraint System (SRS) component. Failure to follow this instruction may result in
incorrect operation of the Supplemental Restraint System (SRS), which increases the risk of serious
personal injury or death in a crash.
WARNING: Never probe the electrical connectors on airbag, Safety Canopy or side air curtain
assemblies. Failure to follow this instruction may result in the accidental deployment of these
assemblies, which increases the risk of serious personal injury or death.
WARNING: Do not handle, move or change the original horizontal mounting position of the
restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to
follow this instruction may result in the accidental deployment of the Safety Canopy and cause serious
WARNING: Do not obstruct or place objects in the deployment path of the Safety Canopy or side
air curtain assembly. Never insert any type of fastener or tie strap around any portion of the Safety
Canopy, side air curtain assembly, or related interior trim panel. Failure to follow this instruction may
result in the Safety Canopy or side airbag curtain module deploying incorrectly and increases the risk
of serious personal injury or death in a crash.
WARNING: Occupant Classification System (OCS) parts are calibrated as an assembly and must
only be replaced in the configuration they are sold. Never separate parts of an assembly. Failure to
follow this instruction may result in incorrect operation of the OCS and increases the risk of serious
Safety Warnings 32
WARNING: Never allow oil, grease, water or foreign contaminants to get on/in the occupant
classification system (OCS) components or electrical connectors. Failure to follow this instruction may
result in incorrect operation of the OCS and increases the risk of serious personal injury or death in a
crash.
WARNING: Always tighten the fasteners of the restraints control module (RCM) and impact sensor
(if equipped) to the specified torque. Failure to do so may result in incorrect restraint system operation,
which increases the risk of personal injury or death in a crash.
WARNING: Always carry or place a live Safety Canopy, or side air curtain module, with the
module and tear seam pointed away from your body. Failure to follow this instruction may result in
serious personal injury or death in the event of an accidental deployment.
WARNING: Always carry out the Zero Seat Weight Test whenever the passenger seat has been
removed from the vehicle or any seat component has been remoed from the seat. Never drive a vehicle
with any seat components removed from an occupant classification system (OCS) equipped seat.
Failure to follow these instructions may result in incorrect operation of the occupant classification
system (OCS), which increases the risk of serious personal injury or death in a crash.
WARNING: Do not paint any airbag trim covers or deployment doors. Paint may cause the airbag
to deploy incorrectly. Failure to follow this instruction may increase the risk of serious personal injury
or death in a crash.
Wheel and Tire Health and Safety Precautions
WARNING: Never inflate a tire that has been run flat without first removing the tire from the wheel
to inspect for damage. A damaged tire can fail during inflation. Failure to follow this instruction may
WARNING: Do not mount tube-type tires on tubeless wheels or tubeless tires on tube-type wheels.
Incorrect combinations could result in tire separation from wheel and may result in serious injury to
WARNING: Cracked wheels can be dangerous. Deflate tires on cracked wheels prior to removal of
wheels from the vehicle. Failure to follow this instruction may result in serious personal injury.
WARNING: Retighten wheel nuts within 160 km (100 mi) after a wheel is reinstalled. For dual rear
wheel (DRW) only, a second retightening is required within 800 km (500 mi). Wheels can loosen after
initial tightening. Failure to follow this instruction may result in serious injury to vehicle occupant(s).
WARNING: Always match the tire size to the wheel size during assembly. Incorrect matching can
result in tire bead damage or tire separation from the wheel. Failure to follow this instruction may
result in serious personal injury to technician or vehicle occupant(s).
WARNING: Do not weld or peen wheels. A wheel needing such repairs must have a new wheel
installed. Failure to follow these instructions may result in wheel failure and serious personal injury.
Safety Warnings 33
Safety Warnings 34

Diagnostic Methods
Effective Diagnostic Techniques
The following diagnostic process is critical for consistently successful diagnoses. Random methods work
inconsistently and often lead to multiple repairs and the accompanying frustration.
Understand and verify the symptom .

Understanding a symptom requires understanding normal operation.
Duplicate the concern. Re-create the same conditions that demonstrated the original concern
(road testing may be necessary).
Determine the responsible system .
Gather data, such as a visual inspection and an OASIS report.
Perform system tests, such as pressure tests or DTC retrieval.
Identify the responsible component .
Test the suspect component and related parts.
Determine the root cause
Examine related components (wiring faults, misalignments, incorrect adjustments) that may
be the actual cause or may have caused the component failure.
Repair all related faults to avoid repeat failures.
Verify the repair has corrected the concern (and not created any new ones) using the identical
conditions that demonstrated the original concern.
Diagnostic Scan Tool Testing
Network Test
Performing a network test is always recommended for analysis of electronic system concerns. Always solve
network issues before addressing individual symptoms or DTCs.
Recommended Practice: REFER to Symptom Chart in Section 418-00 to diagnose a network outage or no
response from an individual module (or modules).
DTC Retrieval
Generally, a good diagnostic strategy is to resolve all on-demand codes related to the system concern.
Retrieving all continuous DTCs can also be beneficial to understand historic issues or issues outside of the
suspect system that may be affecting your concern. On-demand testing should be done to ensure the fault
represented by a continuous DTC is still present.
Continuous Memory Diagnostic Trouble Codes (CMDTCs)
Modules that produce diagnostic trouble codes have a program that evaluates system conditions, normally
while the vehicle or system is in use. Module inputs can be checked for values indicating an electrical fault
with the monitoring circuit or component. Module outputs can be monitored for correct function. Codes are
stored when predefined limits are exceeded and retained even if the ignition is turned off (generally
DTC-retention is for 40+ ignition cycles). Not all continuous codes have a matching on-demand code - and
vice versa; this varies with different modules. For example, some network communication codes are
continuous only. It is important to note that the presence of a continuous DTC does not guarantee that the
fault currently exists.
Diagnostic Methods 35
Ford On-Demand DTCs
Ford Motor Company modules have a unique feature that performs a special diagnostic program at the request
of the technician (using a scan tool). This "On-demand" diagnostic program can exercise system outputs not
normally running when the car is parked and record observed faults. These diagnostic codes are
communicated to the scan tool; they are not recorded in module memory. An on-demand test is an effective
tool for evaluating real input and output conditions during module activity - activity that might not normally
be occurring during service bay conditions. For example, an air suspension module on-demand test can run
the compressor, vent the system, and observe the report from the height sensor even when the car is already at
correct trim height and not requiring height adjustment.
Network Communication DTCs
Network DTCs (U-prefix codes) are often a result of intermittent concerns such as damaged wiring or low
battery voltage occurrences. Additionally, vehicle repair procedures (such as module reprogramming or
diagnostics with modules disconnected) often set network DTCs. Replacing a module to resolve a network
DTC is unlikely to resolve the concern. To prevent recurrence of intermittent network concerns, inspect all
network wiring, especially in-line and module connectors; test the vehicle battery.
Recommended practice: Clear the DTC and retest. If the DTC repeats, test the vehicle communication
network.
DTC Nomenclature (SAE J2012 and ISO 14229)
Many modules use 5-character DTCs followed by a 2-character failure-type code. The failure-type
(sometimes called "fault byte") digits provide information about specific fault conditions such as opens or
shorts to ground. Continuous memory DTCs have an additional 2-character DTC status code suffix to assist in
determining DTC history.
Integrated Diagnostic System (IDS) Scan Tool Usage
If The IDS Scan Tool Does Not Communicate With The VCM
1. Check the VCM power; examine the connectn to the vehicle.

The VCM LED illumination prove-out confirms power and ground from the DLC are
provided to the VCM .
Recommended Practice: REFER to Section 418-00 , No Power to the Scan Tool, to
diagnose no power to the VCM .
2. Check the scan tool connection to the VCM .
3. Follow scan tool instructions to retry.
If The IDS Scan Tool Does Not Communicate With The Vehicle
The IDS scan tool first attempts to communicate with the PCM. After establishing communication with the
PCM, the scan tool then attempts to communicate with all other modules on the vehicle.
1. Verify the scan tool operation with a known good vehicle.
2. Verify the ignition is ON.
3. If an IDS session cannot be established with the vehicle ( IDS may state "No communication can be
established with the PCM"):
Choose "NO" when the scan tool prompts to retry communication.

Enter either a PCM part number, tear tag, or calibration number to identify the vehicle and
start a session.
The PCM part number can be determined from OASIS -- choose "HVBoM" from the
OASIS page and search for the PCM part number
The PCM part number and 4-character tear tag are printed on the PCM label.
Establish a session based on the PCM information (above).
4. Using the tool box menu, run the network test.

Determine if all modules on the network are unresponsive or if only the PCM does not
communicate.
Recommended practice: REFER to Symptom Chart in Section 418-00 to diagnose the
network outage or no response from the PCM.
Measuring Automotive Circuits
Wiring Pin (Terminal) Fit And The Use Of Rotunda Flex Probes
To avoid wiring pin (terminal) damage, Rotunda Flex Probes NUD105-R025D or equivalent must be
used to connect test equipment or jumper wires to pins (terminals).
Male to female pin (terminal) fit is critical for correct connection and durability.
Pin (terminal) fit may be checked by using the mating pin (terminal) to test for normal
separation force (a damaged pin or terminal will have very low separation force from the
mating pin or terminal)
Correctly checking the separation force of small pins (terminals) may require removal of the
connector terminal guide/retainer if it adds drag to the pin (terminal) insertion or removal
Replace damaged connectors or pins (terminals).
Use the Wiring Diagram connector view (cell 150) to identify the correct replacement
connector with pigtail.
Use the Wire Harness Terminal Repair Guide to identify and order the correct replacement
pin and pigtail. Available through Ford Dealers, REFER to FMC dealer website, or REFER to
www.fcs.dealerconnection.com/wire .
Checking Power-Providing Circuits
Measuring a power wire with the intended load disconnected using a DMM will only find open
circuits (open fuse or wire).
Recommended practice: Circuits carrying approximately 200-1000 mA* may be loaded with the
specified test light SGT27000. Measure circuit voltage with a DMM while the test light is connected
and illuminated. A reduction in the voltage present during test-light-loading indicates excessive
circuit resistance.
Recommended practice: Circuits carrying more than one ampere* should be loaded with a device
requiring similar current (e.g., a headlamp bulb may be effective). A reduction in the voltage present
during loading indicates excessive resistance.
*Circuit current is matched to wire gauge/size; Examples:
Conductor sizes of 24 gauge (.5 mm) or smaller are generally used to carry approximately 1
ampere (1000 mA) or less. Use of the test light to load these circuits is appropriate.
Conductor sizes of 20 gauge (.8 mm) or larger are generally used to carry approximately 5
amperes (5000 mA) or more. Match the substitute load (measure substitute load current first
as necessary) to this current level.
Checking Ground-Providing Circuits
The best method of checking ground circuits is to measure the circuit voltage drop during component
operation (or attempted operation).
An ohmmeter may be accurately used if the battery has been disconnected.
Recommended practice: Expect less than 2 ohms for most small diameter (18 gauge and smaller)
wires.
Ohmmeter accuracy is limited to circuits carrying less than approximately 5 amperes (this is due to
the fact that very small resistances, undetectable by a DMM , cause significant voltage loss in higher
current circuits).
DMM ohmmeter readings are easily corrupted by the normal voltage present (battery connected) in
many ground circuits.
Recommended practice: Reverse the leads and check for changes in the measurement.
Reversing the DMM lead connections should never change the resistance measurement
(unless the circuit contains a semi-conductor). Measurement (non-semi-conductor)
differences when leads are interchanged at the test points indicate invalid test results. The
presence of voltage corrupts the reading, and causes the meter reading to change when the
leads are reversed.
Checking Circuit Continuity
Recommended practice: Expect less than 2 ohms of resistance for most wires.
Ohmmeter low-resistance resolution (approximately 0.1 ohm) limits its use to circuits carrying less
than approximately 5 amperes. This is due to the fact that very small resistances, below the resolution
of a DMM , cause significant voltage loss in higher current circuits.
The DMM applies a small amount of voltage to the circuit or component to calculate resistance. As a
result, DMM ohmmeters are very sensitive to any level of voltage present. Voltage present in the
circuit will corrupt the DMM reading.
Checking For Unintended Continuity (Shorts) To Other Circuits
A DMM ohmmeter may be used to detect undesired circuit connections to:

Ground
Other unpowered circuits
Recommended practice: Expect greater than 10,000 ohms of resistance between two separate
circuits; the best result is an open circuit DMM ohmmeter indication (no detected resistance).
Shorts to voltage are checked with a DMM voltmeter
Recommended practice: Turn ignition on (with battery connected) and measure the circuit for any
voltage present (none should be present)
Checking Circuits By Back-Probing A Connector
Back-probing should be a testing method of last resort. It should only be employed where a diagnostic
step requires a circuit to be tested under actual operating conditions. Back-probing is a risky testing
method due to the uncertainty of the probe connection and the possibility of damaging terminals.
Do not force test leads or other probes into connectors. Adequate care must be exercised to avoid
connector terminal damage while ensuring that good electrical contact is made with the circuit or
terminal. Failure to follow these instructions may cause damage to wiring, terminals, or connectors
and subsequent electrical faults.
Use Rotunda Back-Probe Pins POMA6411 to assist in making a good test connection and to
prevent connector or terminal damage during back-probing.
Do not test for the presence of voltage at a single point where zero volts is a possible result (you
cannot tell the difference between a bad probe contact and a zero volt result).
Do not test for continuity/opens (using a DMM ohmmeter) between two points (you cannot tell the
difference between bad probe contacts and an open circuit).
Back-probing may be used where the circuit must be analyzed with the voltage-drop method (if the
circuit carries greater than 5 amperes and no other means of testing will definitively eliminate circuit
resistance as a possible fault). A zero-volt result indicates incorrect test conditions (no current flow)
or bad back-probe connections.
Occasionally, module failure mode behavior will change the operation of a circuit when it is opened
for testing. Back-probing is an acceptable remedy for these testing dilemmas.
Circuit Analysis Using Jumper Wires (Creating Substitute Circuits)
Jumper wires may be employed for circuit analysis.

Cautions:
Always use fused jumper wires - the recommended universal-testing jumper wire fuse is 2-5
amperes; larger fuse ratings should be used only in special circumstances.
Use flex probes or equivalent to prevent connector terminal damage (flex probes are not
intended to carry higher currents necessary to operate motors such as a cooling fan or blower
motor).
Follow workshop manual testing directions when using jumper wires to avoid component or
harness damage due to incorrect jumper connections.
Never repair a circu by adding a new wire in parallel to the old one (overlaying the circuit)
without fully understanding what caused the circuit to fail. Always find, examine, and repair
the fault to correct the root cause and to repair any adjacent wiring that has been damaged.
Checking Modules
Generally, module failure rate is very low and therefore replacement modules usually do not resolve
the root cause. Incorrect replacement of a module is often the result of inadequate testing.
Understand the correct module function.
Make sure programmable parameters are set correctly for the function in question (see the list
in Section 418-01 ).
Resolve DTCs first - as directed by Diagnostic Routines.
Test all inputs, both hard-wired and networked.
Test outputs (see "Checking module switching circuits" below).
Check applicable TSBs for module software changes (flash programming).
Checking module switching circuits.
Using the scan tool module-output command function (e.g., IDS Output State Control) to
activate components is a fast way to confirm an output is capable of being switched on by the
module. Testing that reveals normal module-output function confirms the need to analyze the
module inputs.
Don't apply ground or power directly to module-switched components with jumper wires
(unless directed by a workshop manual procedure), as the component can be damaged by a
direct connecon to ground/power.
SECTION 100-01: Identification Codes 2011 Expedition, Navigator Workshop Manual

Identification Codes
Vehicle Identification Number (VIN)
Vehicle Identification Number (VIN) Locator
The Vehicle Identification Number (VIN) is a 17-digit combination of letters and numbers. The VIN is
stamped on a metal tab riveted to the instrument panel, top upper left of the dash. The VIN number is also
found on the Vehicle Certification (VC) label.
If the VIN plate requires replacement, authorized dealers must contact their respective regional office.
Item Description
1 World Manufacturer Identifier (WMI)
2 Brake type and Gross Vehicle Weight Rating (GVWR)
3 Vehicle line and series
4 Engine type
5 Computer-generated check digit
6 Model year
7 Assembly plant
8 Production sequence number
Identification Codes 41
World Manufacturer Identifier (WMI)
The first 3 VIN positions are the World Manufacturer Identifier (WMI).
1FM - Ford Motor Company, USA, Multi-Purpose Vehicle (MPV)

5LD - Lincoln, USA, MPV (limousine)
5LM - Lincoln, USA, MPV
Brake Type and Gross Vehicle Weight Rating (GVWR)
The fourth VIN position is the vehicle brake type and Gross Vehicle Weight Rating (GVWR) code. All
vehicles use hydraulic brakes.
J - 7,001-8,000 pounds GVWR , active safety belts (all positions) with driver and front passenger air
bags and 1st, 2nd and 3rd row side impact air curtains
Vehicle Line and Series
Positions 5 through 7 indicate vehicle line and series.
J2H - Navigator, Rear Wheel Drive (RWD)

J2J - Navigator, Four-Wheel Drive (4WD)
J3H - Navigator L, RWD
J3J - Navigator L, 4WD
K1F - Expedition EL, RWD , XLT MAX
K1G - Expedition EL, , XLT MAX
K1H - Expedition EL, RWD , Eddie Bauer MAX
K1J - Expedition EL, 4WD , Eddie Bauer MAX
K1K - Expedition EL, RWD , Limited MAX
K2A - Expedition EL, 4WD , Limited MAX
U1F - Expedition, RWD , XLT
U1G - Expedition, 4WD , XLT
U1H - Expedition, RWD , Eddie Bauer
U1J - Expedition, 4WD , Eddie Bauer
U1K - Expedition, RWD , Limited
U2A - Expedition, 4WD , Limited
Engine Type
The eighth VIN position is the engine displacement and number of cylinders.
5 - 5.4L, SOHC, electronic fuel injection, 3V, V8, Flexible Fuel Vehicle (FFV)
Additional engine information can be obtained from the engine tag. Refer to Section 303-01 .
Computer-Generated Check Digit
The ninth VIN position is a government-assigned, computer-generated check digit.
Model Year
The tenth VIN position is the model year code.
B - 2011
World Manufacturer Identifier (WMI) 42

Assembly Plant
The eleventh VIN position is the assembly plant code.
E - Kentucky Truck (Jefferson County, Kentucky)
Vehicle Build Sequence
The last 6 VIN positions are an alphanumeric code for the vehicle build sequence. This is also the vehicle
serial and warranty number.
The serial number can also be found on the engine block, transmission and frame.
A00001-F99999 - Ford Division

J00001-L99999 - Lincoln Division
Vehicle Certification (VC) Label
Vehicle Certification (VC) Label Locator
The Vehicle Certification (VC) label contains the manufacturer name, the month and year of
manufacture, the certification statement and the Vehicle Identification Number (VIN). It also includes
Gross Vehicle Weight Rating (GVWR).
If a vehicle requires replacement of the VC label and is 4 years old or less, an authorized dealer must
submit the VIN to their respective regional office. The regional office will submit a web form to the
assembly plant for the replacement label. Once the label has been printed, a representative from the
regional office will deliver the label to the dealer and witness installation on the vehicle. If a vehicle is
more than 4 years old and requires a replacement label, the dealer must submit a request to the
Department of Motor Vehicles.
Assembly Plant 43
Item Description
1 Exterior paint code
2 Region code
3 District Special Order (DSO)
4 Wheelbase code
5 Interior trim code
6 Tape/paint pinstripe code
7 Radio code
8 Axle code
9 Transmission code
10 Spring code
11 Powertrain calibration information
Exterior Paint Code
Paint codes may be listed as a 2-part code. The first set of characters listed indicate the vehicle
primary body color. The second set of characters listed (if applicable) indicate a 2-tone or accent body
color. All colors are base coat/clear coat.
DX - Dark Pearl Blue

F1 - Vermilion
UG - White Platinum
UH - Tuxedo Black Metallic
UJ - Sterling Gray Metallic
UK - Royal Red
UX - Ingot Silver Metallic
V7 - Golden Bronze
Z1 - Oxford White
Wheelbase
Wheel base codes are as follows:
119 - 3,023 mm (119 in) wheelbase

131 - 3,327 mm (131 in) wheelbase
Vehicle Certification (VC) Label Locator 44

Interior Trim
Interior trim codes are listed as a 2-part code. The fies the trim type. The second character identifies
the interior trim color.
Trim Type
1 - Verona leather (2-tone), 40/40 captain's chairs - Expedition
2 - Verona leather, 40/40 captain's chairs - Expedition
3 - Verona leather, 40/40 captain's chairs with accent - Expedition
4 - Verona leather, Eddie Bauer - Expedition
5 - Aniline leather (perforated) - King Ranch - Expedition
F - Cloth captain's chairs - Expedition
M - Cloth, 40/60 split bench seat - Expedition
T - Premium/SOHO leather, 40/40 captain's chairs - Navigator
Interior Trim Color
C - Camel Tan
L - Medium Light Stone
W - Charcoal Black
Tape/Paint Stripe
Tape and paint stripe codes do not apply.
Radio Type
Radio type and associated codes are as follows:
1 - AM/FM stereo with in-dash 6-disc CD changer and clock

F - AM/FM stereo with CD player, navigation system and clock
S - Premium electronic AM/FM stereo CD player
T - Premium AM/FM stereo with in-dash CD changer and clock
U - Premium AM/FM stereo with in-dash, 6-disc CD changer and THX sound system
X - AM/FM stereo with in-dash, CD changer, THX sound and navigation system
Axle Code
Axle ratios and associated codes are as follows:
15 - 3.31 ratio, non-limited slip

16 - 3.73 ratio, non-limited slip
H6 - 3.73 ratio, limited slip
Additional axle information can be obtained from the axle tag. Refer to
Transmission Code
Transmission type and associated code Is as follows:
6 - 6-speed automatic (6R80)

Additional transmission information can be obtained from the transmission tag. Refer to Section
307-01 .
Spring Codes
Spring codes are listed as a 2-part code. The first set of characters listed identifies the front spring
codes. The second set of characters listed identifies the rear spring codes.
Front Springs
AA - 5L14-3C098-AB
Interior Trim 45
BB - 5L14-3C098-BB
CC - 3L1J-18B036-AA
DD - 5L74-3C098-AC
FF - 3L14-18B036-BA
HH - 3L14-18B036-DA
Rear Springs
11 - 4L14-18W002-AA
33 - 5L14-5A965-BB
44 - 5L14-5A965-AB
55 - 4L1J-18W002-AA
66 - 5L74-5A965-AB
Powertrain Calibration Information
NOTE: Powertrain calibration information is limited to a maximum of 5 characters per line on the
Vehicle Certification (VC) label. Because of this, calibration identification consisting of more than 5
characters will wrap to the second line on the VC VC label. Only the base calibration information is
printed. Revision levels will not appear, however, they can be obtained through a scan tool using the
most current software revision.
Item Description
1 Model year (model year in which calibration strategy was first introduced)
2 Vehicle code
3 Transmission code
4 Unique calibration (designates different hardware to similar vehicles), example: tires or drive
ratios
5 Fleet code (describes fleet to which the vehicle belongs), example: 6 - Evaporative Emission
(EVAP)
6 Certification region (lead region where multiple regions are included in one calibration)
example: A - US federal
Spring Codes 46
7 Revision level (will advance as revisions occur), not printed on label
Model Year
0 - 2000
1 - 2001
2 - 2002
3 - 2003
4 - 2004
5 - 2005
6 - 2006
7 - 2007
8 - 2008
9 - 2009
A - 2010
B - 2011
Vehicle Line
TB7 - Expedition
TB5 - Navigator
Transmission
1 - Automatic transmission
Unique Calibration
The Emissions/corporate average fuel economy/carbon dioxide compliance department is responsible

for assigning these calibration numbers. Unique calibration identifications are assigned to cover
similar vehicles to differentiate between tires, drive configurations, final drive ratios and other
calibration-significant factors.
These 2 characters are chosen by the analyst to provide identifiable information unique to each
calibration. For example, using the number 2 to denote a 2-valve engine versus using the number 4 to
denote a 4-valve engine provides an easily identifiable difference.
Fleet Code
1 - Heavy duty gas engine/Dyno
2 - Fast-Automobile Manufacturers' Association, US
3 - Alternative durability protocol, US
4 - Not assigned
5 - Not assigned
6 - Evaporative Emission (EVAP)
7 - Mileage accumulation, aging endurance durability
8 - On-Board Diagnostic (OBD)
9 - Not assigned
Certification Region
Where multiple regions are included in one calibration, only the lead region will appear.
5 - US 50 states
A - US Federal, including altitude, may include Canada and/or Mexico
B - US California Standard, includes US green states
C - Canada
D - China
E - European Community (Austria, Belgium, Denmark, Finland, France, Germany, Greece,
Ireland, Italy, Luxembourg, Netherlands, Portuded European Community (E plus Croatia,
Czech Republic, Estonia, Hungary, Norway, Poland, Romania, Russian Federation, Slovakia,
Slovenia, Switzerland and Yugoslavia)
G - Gulf Cooperative Council (Bahrain, Kuwait, Oman, Qatar, Saudi Arabia and United Arab
Emirates)
Unique Calibration 47
H - Hong Kong
J - Japan
K - Korea
L - Malaysia
M - Mexico
N - New Zealand
P - Australia
Q - South America (Brazil)
S - Singapore
T - Taiwan
U - South America (unleaded fuel regions)
V - Vietnam
X - Rest Of World (ROW)
Y - Military
Z - Israel
Revision Level (not printed on label)
91-99 - Hardware certification levels
01-04 - Preliminary levels
00 - Job 1 production (initial calibration)
05-09 - Pre-job 1 revisions to calibrations
10-89 - Post-job 1 revisions to calibrations
0B - Durability test level
BD - OBD intermediate level (pre-05)
Unique Calibration 48
SECTION 100-02: Jacking and Lifting 2011 Expedition, Navigator Workshop Manual
Jacking and Lifting
Jacking Points - Front
WARNING: Shut off the electrical power to the air suspension system prior to hoisting or jacking
an air suspension equipped vehicle. Failure to do so may result in unexpected inflation or deflation of
the air springs, which may result in shifting of the vehicle during these operations. Failure to follow this
instruction may result in serious personal injury.
WARNING: Turn off (disable) the power running boards (if equipped) before jacking, lifting or
placing any object under the vehicle.
Never place your hand between the power running board and the vehicle. Extended power running
boards will retract when doors are closed.
WARNING: When jacking or lifting the vehicle, block all wheels remaining on the ground. Set the
parking brake if the rear wheels will remain on the ground. These actions help prevent unintended
vehicle movement. Failure to follow these instructions may result in serious personal injury.
WARNING: Never get underneath a vehicle that is supported only by a jack. The jack could
unintentionally lower. Always support vehicle with floor stands. Failure to follow these instructions
WARNING: Only raise the vehicle when positioned on a hard, level surface. Attempting to raise the
vehicle on an uneven or soft surface may result in vehicle slipping or falling from the jack or jackstand.
Failure to follow this instruction may result in serious personal injury.
WARNING: Identify the correct jacking points by locating the triangle stamped into the uni-body
sheet metal or vehicle frame. Raising a vehicle in any other location may result in vehicle shifting or
falling. Failure to follow this instruction may result in serious personal injury.
NOTICE: The jack provided with the vehicle is intended to be used in an emergency for changing a
deflated tire. To avoid damage to the vehicle, never use the jack to hoist the vehicle for any other
purpose.
NOTICE: To prevent possible damage to the underbody, do not drive the vehicle onto the drive-on lift
without first checking for possible interference.
NOTICE: Damage to the suspension, exhaust or steering linkage components may occur if care is not
exercised when positioning the hoist adapters prior to lifting the vehicle.
Jacking and Lifting 49

Disable the air suspension system. Refer to Section 204-05 .
The front jacking point is indicated by an arrow cutout in the frame, located behind the front tire and wheel.
After the vehicle has been lowered, enable the air suspension system. Refer to Section 204-05 .
Jacking Points - Rear
NOTICE: /i> Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and
adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to contact
the cover at any point where the cover joins the housing.
The rear jacking point is indicated by an arrow cutout in the frame, located in front of the rear tire and wheel.
Jacking and Lifting 50

Lifting Points - Front and Rear
Locate the front hoist adapters and rear hoist adapters as indicated.
Lifting Points - Front and Rear 51

SECTION 100-03: Maintenance Schedule 2011 Expedition, Navigator Workshop Manual

Maintenance Schedules - Gasoline Engines
For Maintenance Schedule information, refer to the Scheduled Maintenance Guide chapter in the Owner's
Guide.
Also available at:
www.motorcraftservice.com and select Owner Guides.
Maintenance Schedules - Gasoline Engines 52

SECTION 100-04: Noise, Vibration and Harshness 2011 Expedition, Navigator Workshop Manual
Noise, Vibration and Harshness (NVH)
Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling,
that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue
where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a
firmer than usual response from the suspension system. NVH is a term used to describe these conditions,
which result in varying degrees of dissatisfaction. Although a certain level of NVH caused by road and
environmental conditions is normal, this section is designed to aid in the diagnosis, testing and repair of NVH
symptoms.
Acceptable NVH
All internal combustion engines and drivelines produce some noise and vibration; operating in a real world
environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these
to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when
actually the sounds are normal for the vehicle type. As a technician, it is very important to be familiar with
vehicle features and know how they relate to NVH symptoms and their diagnosis. For example, if the vehicle
has automatic overdrive, it is important to test drive the vehicle both in and out of overdrive mode.
Glossary of Terms
Amplitude
The quantity or amount of energy produced by a vibrating component (G-force). An extreme vibration has a
high amplitude. A mild vibration has a low amplitude. See Intensity.
Boom
Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming.
Buffet/Buffeting
Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass.
Buzz
A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a
high-frequency vibration. Vibration feels similar to an electric razor.
Chatter
A pronounced series of rapidly repeating rattling or clicking sounds.
Chirp
A short-duration, high-pitched noise associated with a slipping drive belt.
Noise, Vibration and Harshness (NVH) 53

Chuckle
A repetitious, low-pitched sound. A loud chuckle is usually described as a knock.
Click
A sharp, brief, non-resonant sound, similar to actuating a ball point pen.
Clonk
A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as
hammering.
Clunk/Driveline Clunk
A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or
decelerating abruptly. Also described as a thunk.
Conductor
The components that carry (transmit) a vibration frequency from the originator to the reactor.
Cycles Per Second
Cycles per second. Same as hertz (Hz).
Cracks
A mid-frequency sound, related to squeak. Sound varies with temperature conditions.
Creak
A metallic squeak.
Cycle
The process of a vibrating component going through a complete range of motion and returning to the starting
point.
Decibel (dB)
A unit of measurement, referring to sound pressure level, abbreviated dB.
Drone
A low-frequency, steady sound, like a freezer compressor. Also described as a moan.
Drumming
A cycling, low-frequency, rhythmic noise often accompanied by a sensation of pressure on the ear drums.
Also described as a low rumble, boom or rolling thunder.
Flutter
Mid to high intermittent sound due to air flow. Similar to a flag flapping in the wind.
Chuckle 54
Frequency
The rate at which a cycle occurs within a given time.
G-force
The additional load or weight produced in an object during acceleration. When measuring the level or
amplitude of a vibration without sound, the unit G is added to associate the force of the vibration to gravity.
This is similar to measuring the weight of an object, which is also a function of gravity.
Gravelly Feel
A grinding or growl in a component, similar to the feel experienced when driving on gravel.
Grind
An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood.
Hertz (Hz)
A unit of measure used to describe noise and vibration concerns expressed in cycles per second.
Hiss
Steady, high-frequency noise. Vacuum leak sound.
Hoot
A steady, low-frequency tone, sounds like blowing over a long neck bottle.
Howl
A mid-range frequency noise between drumming and whine. Also described as a hum.
Hum
Mid-frequency steady sound, like a small fan motor. Also described as a howl.
Intensity
The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher
the sound's amplitude, the higher the intensity and vice versa. See Amplitude.
Knock
A heavy, loud, repetitious sound, like a knock on the door.
Moan
A constant, low-frequency tone. Also described as a hum.
Ping
A short-duration, high-frequency sound, which has a slight echo.
Frequency 55
Pitch
The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice
versa.
Pumping Feel
A slow, pulsing movement.
Rattle
A random and momentary or short-duration noise.
Reactor
The component, or part, that receives a vibration from an originator and conductor and reacts to the vibration
by moving.
Roughness
A medium-frequency vibration. A slightly higher frequency than a shake. This type of vibration is usually
related to drivetrain components.
Rustling
Intermittent sound of varying frequency, sounds similar to shuffling through leaves.
Shake
A low-frequency vibration, usually with visible component movement. Usually relates to tires, wheels, brake
drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as
a shimmy or wobble.
Shimmy
An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft
rotation. Also described as waddle.
Shudder
A low-frequency vibration that is felt through the steering wheel or seat during light brake application.
Slap
A resonance from flat surfaces, such as safety belt webbing or door trim panels.
Squeak
A high-pitched transient sound, similar to rubbing fingers against a clean window.
Squeal
A long-duration, high-pitched noise.
Pitch 56
Tap
A light, rhythmic or intermittent hammering sound, similar to tapping a pencil on a table edge.
Thump
A dull beat caused by 2 items striking together.
Tick
A rhythmic tap, similar to a clock noise.
Tip-In Moan
A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph).
Transient
A noise or vibration that is momentary, a short duration.
Vibration
Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and
down.
Whine
A constant, high-pitched noise. Also described as a screech.
Whistle
High-pitched noise with a very narrow frequency band. Examples of whistle noises are a turbocharger or air
flow around an antenna.
Wind Noise
Any noise caused by air movement in, out or around the vehicle.
Tap 57
Wind Noise 58
SECTION 100-04: Noise, Vibration and Harshness 2011 Expedition, Navigator Workshop Manual
DIAGNOSIS AND TESTING Procedure revision date: 08/12/2010
Noise, Vibration and Harshness (NVH)
Special Tool(s)
Electronic Vibration Analyzer

100-F027 (014-00344) or equivalent
EngineEAR
107-R2100 or equivalent
EngineEAR/ChassisEAR
Mastertech Series MTS 4000 Driveline

Balance and NVH Analyzer (Vetronix)
257-00018 or equivalent.
Squeak and RattleRepair Kit
164-R4900
Ultrasonic Leak Detector

Diagnostic Theory
The shortest route to an accurate diagnosis results from:
system knowledge, including comparison with a known good system.

system history, including repair history and usage patterns.
condition history, especially any relationship to repairs or sudden change.
knowledge of possible sources.
using a systematic diagnostic method that divides the system into related areas.
The diagnosis and correction of NVH symptoms requires:
a road or system test to determine the exact nature of the symptom.

an analysis of the possible causes.
testing to verify the cause.
repairing any symptoms found.
a road test or system test to make sure the cause has been corrected or brought back to within an
acceptable range.
Diagnostic Procedure Overview
Qualifying the symptom by the particular sensation present can help narrow down the cause. Always use the
"symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the
Noise, Vibration and Harshness (NVH) 59

problem into related areas to correct the customer concern.
Verify the "symptom".

Determine which "system(s)" can cause the "symptom" using the diagnostic tools described in this
section.
If a vibration symptom is vehicle speed related, the tire and wheel rpm/frequency and
driveshaft frequency should be calculated.
If a vibration symptom is engine speed related, the engine, engine accessory and engine firing
frequencies should be calculated.
After determining the possible "system(s)", refer to the appropriate section in this manual to identify
the worn or damaged "components".
After identifying the "components", identify the "cause" of the failure.
Remember that the vibrating source component (originator) may only generate a small vibration. This small
vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor),
due to contact with other components (transfer path).
The diagnostic tools allow for a systematic collection of information that is necessary to accurately diagnose
and repair NVH problems. For the best results, carry out the test as follows:
a. Test drive the vehicle with the vibration sensor inside the vehicle.
b. Place the sensor in the vehicle according to feel.
If the condition is felt through the steering wheel, the source is most likely in the front of the
vehicle.
A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive
axle or rear wheels and tires.
c. Record the readings. Also note when the condition begins, when it reaches maximum intensity and if
it tends to diminish above/below a certain speed.
Frequencies with an amplitude reading of 0.06 Gs or less are barely perceptible NVH levels.
No corrective action is necessary.
d. Place the vibration sensor on or near the suspect area outside the vehicle.
e. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading.
f. Compare the readings.
A match in frequency indicates the problem component or area.
An unmatched test could indicate the symptom is caused by the engine, torque converter or
engine accessory. Use the diagnostic tools in the rpm mode and check if symptom is rpm
related.
Tools and Techniques
The following diagnostic tools and techniques can be used separately or in conjunction with each other to aid
in the diagnosis of NVH symptoms. They are listed in order of preference for ease in their use for locating
these symptoms.
NVH Analyzer (Vetronix)
The MTS 4000 and the MTS 4100 NVH analyzers are tools to aid in the identification and isolation of a
noise, vibration or harshness symptom in a vehicle. They measure noise and vibration data and compare it
with data obtained from the vehicle's PCM as well as vehicle variants that were entered by the user such as
pulley size, axle ratio and tire size in order to provide possible sources. The MTS 4000 and the MTS 4100
have the following characteristics:
Interface with the vehicle's computer system

Support and store vibration data input from 1 or 2 accelerometers
NVH Analyzer (Vetronix) 60

Support and store noise data input from 2 microphones
Provide a photo-tachometer for operation of the driveshaft balancing function
Provide a strobe output capable of driving a standard timing light
Contain a real-time clock circuit that provides time and date information which is used for tagging test
data
Have the capability to print to an external printer and interface with a PC
Can be powered from a variety of power sources: cigarette lighter, AC power or the internal battery
pack
The MTS 4000 and the MTS 4100 NVH analyzers have 4 main operating modes. The first is for vibration
diagnosis. This mode measures data from 1 or 2 accelerometers simultaneously while obtaining data from the
vehicle. Then it carries out a frequency analysis on the accelerometer information and compares the vibration
frequencies with the frequencies associated with various rotating components within the vehicle. The data can
be presented in 4 different display modes: principle component, bar chart, frequency spectrum or waterfall.
All display mode formats contain the same common elements, such as amplitude.
The second is for noise diagnosis. This mode measures noise from 1 or 2 microphones simultaneously. All
noise measurements are in decibels (dBs). All frequency bands used for noise measurements are the same as
for the vibration measurements, up to 1,000 Hz.
The third is driveshaft balancing. Driveshaft balancing is done using 1 or 2 accelerometers and a
photo-tachometer. The accelerometers measure the vibration at both ends of the driveshaft, while the
photo-tachometer measures the rotation speed and position reference. Refer to Section 205-00 .
The fourth is the strobe. A strobe or standard timing light can be connected to an analyzer, to provide a means
for measuring rotation speed. The strobe function is used for isolating the source of a vibration.
Electronic Vibration Analyzer (EVA)
The Electronic Vibration Analyzer (EVA) is a hand-held electronic scan tool which will assist in locating the
source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for
testing purposes. The unit displays the 3 most common vibration frequencies and their corresponding
amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude)
of each vibration being displayed and its relative G-force. The keypad is arranged to make the EVA simple to
program and use. Some of the functions include the ability to average readings as well as record, play back
and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating
components such as a driveshaft or engine accessories.
Item Description
1 Electronic Vibration Analyzer (EVA) screen
2 Frequency mode displayed in rpm or Hz
3 Active sensor input (A or B)
4 Current active mode
5 G-force indicators or the strongest frequencies in descending strength of each vibration
Electronic Vibration Analyzer (EVA) 61

6 Strength of each vibration

7 Frequency in rpm/Hz of each vibration
Record the readings taken with the diagnostic tool.
Frequencies should be read in the "average" mode.

Frequencies have a range of plus or minus 2 Hz. A reading of 10 Hz can be displayed as an 8 Hz
through 12 Hz.
Vibrate Software
Vibrate Software (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the
source of unacceptable vibrations. The engine's crankshaft is the point of reference for vibration diagnosis.
Every rotating component will have an angular velocity that is faster, slower or the same as the engine's
crankshaft. Vibrate Software calculates the angular velocity of each component and graphically represents
these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how
Vibrate Software helps diagnose a vibration symptom:
Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire,
driveshaft and engine vibrations.
Print a Vibration Worksheet graph. The printed graph is to be used during the road test.
Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration
frequency rpm and the engine rpm on the worksheet graph. The point on the graph where the
vibration frequency rpm reading and the engine rpm reading intersect indicates the specific
component group causing the symptom.
A frequency measurement tool capable of measuring vibration frequency and engine rpm will
be needed.
Provides graphics of diagnostic procedures to aid in testing components.
Reed Tachometer
The Reed tachometer is a hand-held vibration sensor which will assist in locating the source of unacceptable
vibrations. The vibration sensor can be placed anywhere in the vehicle for testing purposes. The Reed
tachometer contains several reeds that are tuned to vibrate or resonate at different frequencies ranging from 10
to 80 Hz or 600 to 4800 rpm. Though the Reed tachometer is able to measure multiple frequencies, it does not
mre amplitude.
Sirometer
The Sirometer measures frequency in hertz and rpm. To use the Sirometer, place it on any vibrating
component and slowly scroll the wire out by turning the knob. As the length of wire changes, so does its
natural frequency. Find the length of wire that vibrates with the highest amplitude. This frequency will match
that of the vibrating component. Read the frequency for that length of wire.
Combination EngineEAR/ChassisEAR
An electronic listening device used to quickly identify noise and the location under the chassis while the
vehicle is being road tested. The ChassisEARs can identify the noise and location of damaged/worn wheel
bearings, constant velocity joints, brakes, springs, axle bearings or driveshaft carrier bearings.
EngineEAR Basic Unit
An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of
damaged/worn bearings in generators, coolant pumps, A/C compressors and power steering pumps. They are
Vibrate Software 62
also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise.
The EngineEAR has a sensing tip, amplifier and headphones. The directional sensing tip is used to listen to
the various components. Point the sensing tip at the suspect component and adjust the volume with the
amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations,
generated by or passing through, the component. Various volume levels can reveal different sounds.
Mechanic's Stethoscope
A mechanic's stethoscope is an inexpensive tool for locating noises in engines and other moving parts. It can
be used to help diagnose piston slap, worn gears, faulty valves, coolant pump failure, damaged gaskets,
defective bearings and body squeaks.
Squeak and Rattle Repair Kit
The Squeak and Rattle Repair Kit (Rotunda tool number 164-R4900) contains lubricants and self-adhesive
materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the
following materials:
PVC (soft foam) tape

Urethane (hard foam) tape
Flocked (black fuzzy) tape
UHMW (frosted) tape
Squeak and rattle oil tube
Squeak and rattle grease tube
Ultrasonic Leak Detector
The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is
weatherstripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative
emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the
ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the
vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is
approached, a beeping sound is produced which increases in both speed and frequency.
Write-Up Job Aid
To assist the service advisor and the technician, a Write-Up Job Aid used during the interview process is
included with this material. The Write-Up Job Aid serves as a place to record all important symptom
information.
EngineEAR Basic Unit 63

1: Customer Interview
The diagnostic process starts with the customer interview. The service advisor must obtain as much
information as possible about the symptom and take a test drive with the customer. There are many ways a
customer will describe NVH symptoms and this will help minimize confusion arising from descriptive
language differences. It is important that the symptom is correctly interpreted and the customer descriptions
are recorded. During the interview, complete the Write-Up Job Aid and ask the following questions:
When was it first noticed?

Did it appear suddenly or gradually?
Did any abnormal occurrence coincide with or precede its appearance?
Use the information gained from the customer to accurately begin the diagnostic process.
2: Pre-Drive Check
It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the
vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle.
The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything
that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle
on the road.
3: Preparing for the Road Test
Observe the following when preparing for the road test:
Review the information recorded on the Write-Up Job Aid. It is important to know the specific
symptom the customer has with the vehicle.
Do not be misled by the reported location of the noise/vibration. The cause can actually be some
Ultrasonic Leak Detector 64

distance away.
Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal
testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in
which the condition occurs.
While observing that they are not related to the symptom, eliminate the following:
If possible, lower the radio antenna in order to minimize turbulence.
Identify anything that could potentially make noise or be a source of wind noise.
Inspect the vehicle for add-on items that create vibration/noise.
Turn off the radio and the heating and cooling system blower.
The engine speed is an important factor in arriving at a final conclusion. Therefore, connect a
diagnostic tool, Vertronix, or an accurate tachometer to the engine, even if the vehicle has a
tachometer. This will make sure of an exact engine speed reading.
4: Verify the Customer Concern
Verify the customer concern by carrying out a road test, an engine run-up test or both.
The decision to carry out a road test, an engine run-up test or both depends on the type of NVH symptom. A
road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A Drive
Engine Run-Up (DERU) or a Neutral Engine Run-Up (NERU) test identifies noises and vibrations relating to
engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests,
however, they will eliminate many possibilities if carried out correctly.
5: Road Test
NOTE: It may be necessary to have the customer ride along or drive the vehicle to point out the symptom.
During the road test, take into consideration the customer's driving habits and the driving conditions. The
customer's concern just may be an acceptable operating condition for that vehicle.
The following is a brief overview of each test in the order in which it appears. A review of this information
helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After
reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this
process.
The Slow Acceleration Test is normally the first test to carry out when identifying an NVH symptom,
especially when a road test with the customer is not possible.
The Heavy Acceleration Test helps to determine if the symptom is torque-related.
The Neutral Coast Down Speed Test helps to determine if the symptom is vehicle speed-related.
The Downshift Speed Test helps to determine if the symptom is engine speed-related.
The Steering Input Test helps to determine how the wheel bearings and other suspension components
contribute to a vehicle speed-related symptom.
The Brake Test helps to identify vibrations or noise that are brake related.
The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy
surface.
The Engine Run-Up Tests consist of the Neutral Engine Run-Up (NERU) Test and the Drive Engine
Run-Up (DERU) Engine Test. These tests help to determine if the symptom is engine speed-related.
The Neutral Engine Run-Up (NERU) Test is used as a follow-up test to the Downshift Speed Test
when the symptom occurs at idle.
The Drive Engine Run-Up (DERU) Load Test helps to identify vibration/noise sensitive to engine
load or torque. It also helps to reproduce engine speed-related symptoms that cannot be duplicated
when carrying out the Neutral Engine Run-Up (NERU) Test or the Neutral Coast Down Test.
The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related

symptoms.
The Vehicle Cold Soak Procedure helps to identify symptoms occurring during initial start-up and
when an extended time lapse occurs between vehicle usage.
Slow Acceleration Test
To carry out this test, proceed as follows:
Slowly accelerate to the speed where the reported symptom occurs. Note the vehicle speed, the engine
rpm and, if possible, determine the vibration frequency.
Attempt to identify from what part of the vehicle the symptom is coming.
Attempt to identify the source of the symptom.
If the source of the symptom has been identified as a result of this test, proceed to the appropriate
section for further diagnosis and repair. If the source has not been identified, continue with the road
test.
Heavy Acceleration Test
Accelerate hard from 0-64 km/h (0-40 mph).

Decelerate in a lower gear.
The symptom is torque related if duplicated while carrying out this test.
test.
Neutral Coast Down Speed Test
Drive at a higher rate of speed than where the symptom occurred when carrying out the Slow
Acceleration Test.
Place the transmission in NEUTRAL and coast down past the speed where the symptom occurs.
The symptom is vehicle speed-related if duplicated while carrying out this test. This eliminates the
engine and the torque converter as sources.
If the symptom was not duplicated while carrying out this test, carry out the Downshift Speed Test to
verify if the symptom is engine speed related.
test.
Downshift Speed Test
Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test.
Drive at the engine rpm where the symptom occurs.
The symptom is engine speed related if duplicated while carrying out this test. This eliminates the
tires, wheels, brakes and the suspension components as sources.

If necessary, repeat this test using other gears and neutral to verify the results.
test.
Steering Input Test
Drive at the speed where the symptom occurs, while making sweeping turns in both directions.
If the symptom goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of
Four-Wheel Drive (4WD) applications), and tire tread wear are all possible sources.
test.
Brake Test
With the brake released, accelerate the vehicle. While coasting (brake pedal released) to a stop in
NEUTRAL, note any abnormal rate of deceleration. Abnormal deceleration could indicate a parking
brake or service brake that is not fully releasing.
Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light
braking applications.
Accelerate to 89-97 km/h (55-60 mph). Moderately apply the brakes and slow the vehicle to a stop.
A brake vibration can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard
upon brake application and should diminish when the brake is released. For vehicles with separate
park brake shoes, noise or vibration from the parking brake system will not be affected by applying
the hydraulic brakes. On these systems, the parking brake system requires inspection if a parking
brake concern is suspected.
brake section(s) for further diagnosis and repair. If the source has not been identified, continue with
the road test.
Road Test Over Bumps
Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is
coming from the front or the back and the left or the right side of the vehicle.
test.
Neutral Engine Run-Up (NERU) Test
Install a tachometer.

Increase the engine rpm up from an idle to approximately 4,000 rpm while in PARK on Front Wheel
Drive (FWD) vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the
engine rpm and, if possible, determine the vibration frequency.
Attempt to identify what part of the vehicle the symptom is coming from.
Attempt to identify the source of the symptom.
test.
Drive Engine Run-Up (DERU) Load Test
WARNING: Block all wheels, set the parking brake and firmly apply the service brake to reduce the
risk of vehicle movement during this procedure. Failure to follow these instructions may result in
NOTICE: Do not carry out the Engine Load Test for more than 5 seconds or damage to the
transmission or transaxle may result.
Block the front and rear wheels.

Apply the parking brake and the service brake.
Install a tachometer.
Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to
approximately 2,000 rpm. Note the engine rpm and, if possible, determine the vibration frequency.
Repeat the test in REVERSE.
If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or
transaxle mounts.
If the symptom is definitely engine speed-related, carry out the Engine Accessory Test to narrow
down the source.
test.
Engine Accessory Test
WARNING: Block all wheels, set the parking brake and firmly apply the service brake to reduce the
risk of vehicle movement during this procedure. Failure to follow these instructions may result in
NOTICE: Limit engine running time to one minute or less with belts removed or serious engine damage
will result.
NOTE: Use a frequency measurement tool to pinpoint accessory vibrations. A listening device, such as an
EngineEAR, will also help to identify noises from specific accessories.
Remove the accessory drive belt(s).

Increase the engine rpm to where the symptom occurs.
If the vibration/noise is duplicated when carrying out this test, the belt(s) and accessories are not
sources.

If the vibration/noise was not duplicated when carrying out this test, install the accessory belt(s), one
at a time, to locate the source.
test.
Vehicle Cold Soak Procedure
To carry out this procedure, proceed as follows:
Test preparations include matching customer conditions (if known). If not known, document the test
conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to
3 minutes.
Park the vehicle where testing will occur. The vehicle must remain at or below the symptom
temperature (if known) for 6-8 hours.
Before starting the engine, conduct a visual inspection under the hood.
Turn the key on, but do not start the engine. Listen for the fuel pump, ABS and air suspension system
noises.
Start the engine.
Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the
general location of the vibration/noise. Then, search for a more precise location by using a
stethoscope or EngineEAR.
test.
Classify NVH Symptom
For NVH concerns, it is necessary to classify the customer's concern into one of the 3 categories: noise,
vibration or harshness. The reason for this is that a customer concern may consist of a combination of
symptoms involving noise and vibration, or vibration and harshness. In cases where there are combination
symptoms, the technician will need to know which diagnostic path to follow: noise, vibration or harshness.
For example, if a customer has a concern involving a noise and a vibration, and it is determined that it is
vehicle speed-related, the vibration diagnostic path would be followed.
Noise Symptoms
Once a symptom is classified as a noise, the particular conditions under which the noise occurs need to be
identified. These conditions are identified and verified during the road test. For example, a noise may only
occur while turning. The next step is to determine which systems on the vehicle are related to that condition.
In this case, the steering system and wheel/tire system may be suspect. After identifying possible systems, a
preliminary inspection of these systems should be done. If the source of noise is still unidentified, use a
listening device (such as the ChassisEAR) to pinpoint the source. Once the source has been identified,
determine if this source is related to the suspected system previously identified. If it is related, then complete
the repair to resolve the customer concern. If it is unrelated, then it is possible that the source of the noise is a
reactor to a noise being transmitted through a transfer path. If this is the case, repairing the reactor will not
resolve the customer concern. The transfer path must be identified and a determination made if the noise is
normal, but accentuated by the transfer path (conductor), or if the originator is the fault causing excessive
noise to transfer to another component through a conductor. There is a relationship between systems identified
as related to conditions and the noise transfer path. In some cases, the condition under which the noise occurs
has nothing to do with the identified source. This relationship is important in the diagnosis of noise concerns.

It is the first clue that the identified source of noise might be a reactor and that further investigation is needed
to diagnose a possible noise transfer path concern. Based on the results from the road test, make a
determination of which action in the symptom chart to take first.
Vibration Symptoms
Most vibrations consist of movements back and forth or up and down that repeat. Every time the vibrating
component goes through its complete range of motion and returns to the starting point is called a cycle. The
rate at which these cycles occur within a given time is called the frequency. Frequency is measured in cycles
per second or Hertz (Hz). One cycle per second equals one Hz. Once the frequency of a vibration is known,
calculations can be done to determine the system that is the source of the concern.
Order of Vibration
The order of a vibration refers to how often the vibration is present in one revolution of the component. For
example, a vibration that is present once each revolution of a component would be a first order vibration. A
vibration present twice each revolution of the component would be a second order vibration. Vibration orders
do not have to be whole numbers, they can have decimal values such as 1.5 order vibration or 3.08 order
vibration.
The concept of order of vibration is important to remember when the measured frequency of a vibration does
not seem to match the frequency calculations of any of the likely systems or components. As the order
increases, the frequency of the vibration will also increase by a multiple of that number.
For example, vibration may be present where the frequency is measured at 14 Hz. After doing the necessary
calculations it is determined the first order tire and wheel frequency is 7 Hz and the first order driveshaft
frequency is 22 Hz. Based on this information it can be determined the vibration is most likely a second order
tire and wheel vibration: 7 Hz (first order tire and wheel frequency) multiplied by 2 (second order) equals 14
Hz (second order tire and wheel frequency).
Relationship of Vibration Frequency to Order of Vibration
After carrying out the road test as described in this section, the vibration was determined to be either
vehicle-speed related or engine-speed related. That determination will identify the vibration frequency
calculations that should be done.
Vibration Type Calculate

Vehicle-speed related Tire-speed vibration frequency
Driveshaft-speed vibration frequency

Engine-speed related Engine vibration frequency
Engine accessory vibration frequency
Engine firing vibration frequency

In calculating and using frequency readings, it is important to remember the direct relationship between Hz
and rpm. One Hz is equal to 60 rpm. This is easy to remember by thinking of Hz as cycles per second. There
are 60 seconds in a minute, therefore, multiply the Hz reading by 60 to get rpm. Conversely, divide rpm by 60
to get Hz.
Use the Frequency and RPM Calculations Worksheet to calculate system/component frequencies. The
worksheet provides the necessary steps to determine each system/component group frequency.
Frequency Calculations
Calculating Tire and Wheel Frequency
For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and
wheel rpm and frequency by carrying out the following:
Measure the diameter of the tire.

Record the speed at which the vibration occurs.
Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency
Chart.
If the vehicle speed is not listed, calculate the tire and wheel frequency as follows:
Divide the vehicle speed at which the vibration occurs by 16 km/h (10 mph). Multiply that
number by the 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide
that number by 60.
For example, if calculating the frequency based on vehicle speed in km/h for a 64 km/h
vibration with 835 mm tires, divide 64 km/h by 16 km/h = 4. Multiply 4 by 105 rpm = 420.
Divide 420 by 60 seconds = 7 Hz at 64 km/h.
If calculating the frequency based on vehicle speed in mph for a 40 mph vibration with 33
inch tires, divide 40 mph by 10 mph = 4. Multiply 4 by 105 rpm = 420. Divide 420 by 60
seconds = 7 Hz at 40 mph.
The calculated frequency of 7 Hz is the first order tire and wheel vibration; the second order
tire and wheel vibration would be twice this number at 14 Hz; the third order tire and wheel
vibration would be 21 Hz; and so on.
Tire Speed and Frequency Chart
Tire Diameter Tire RPM/Hz Tire RPM/Hz Tire RPM/Hz Tire RPM/Hz
mm (in) @ 16 km/h (10 mph) @ 80 km/h (50 mph) @ 97 km/h (60 mph) @ 113 km/h
(70 mph)
483 (19) 182 910/15 1,092/18 1,274/21
508 (20) 173 865/14 1,038/17 1,211/20
533 (21) 165 825/14 990/16 1,155/19
560 (22) 158 790/13 948/16 1,106/18
585 (23) 151 755/13 906/15 1,057/18
610 (24) 145 725/12 870/14 1,015/17
635 (25) 139 695/12 834/14 973/16
660 (26) 134 670/11 804/13 938/16

685 (27) 129 645/11 774/13 903/15

710 (28) 124 620/10 744/12 868/14
735 (29) 119 595/10 714/12 833/14
760 (30) 115 575/10 690/11 805/13
785 (31) 111 555/9 666/11 777/13
810 (32) 108 540/9 648/11 756/13
835 (33) 105 525/9 630/10 735/12
864 (34) 102 510/8 612/10 714/12
Calculating Driveshaft Frequency
Knowing the tire and wheel frequency allows for easy calculation of driveshaft frequency. The driveshaft
drives the tires through the rear axle. Therefore, to determine driveshaft frequency, multiply tire and wheel
frequency by the ratio of the rear axle. Calculate driveshaft frequency by performing the following steps:
Obtain the axle ratio of the vehicle. Suppose the vehicle you are diagnosing has a vibration problem at
64 km/h (40 mph) and a rear axle ratio of 3.08:1.
Multiply the tire and wheel frequency of 7 Hz (calculated previously) with the rear axle ratio of
3.08:1. This results in a driveshaft frequency of 22 Hz at a vehicle speed of 64 km/h (40 mph).
The calculated frequency of 22 Hz is the first order driveshaft frequency; the second order frequency of the
driveshaft is twice this number, or 44 Hz; and so on.
Calculating Engine Frequency
Use the engine rpm where the vibration symptom occurs to determine engine frequency. Calculate engine
frequency by dividing the engine rpm by 60 (the number of seconds in a minute). For example, if the
corresponding engine rpm of a vibration concern on a vehicle is 2,400 rpm, the resulting engine frequency is
40 Hz. Therefore, a 40 Hz vibration is a first order engine vibration. For purposes of vibration diagnosis, the
engine also includes the torque converter and exhaust system.
Calculating Engine Accessory Frequency
Belt-driven engine accessories often produce vibrations at different frequencies than the engine itself. This is
because the drive ratio created by the different size pulleys causes them to rotate at different speeds.
Determining engine accessory frequency is comparable to calculating driveshaft frequency.
Calculate engine accessory frequency by performing the following steps:
Determine the size ratio factor between the accessory pulley and the crankshaft pulley. For example,
if the diameter of the crankshaft pulley is 6 inches and the accessory pulley diameter is 2 inches, the
accessory pulley rotates 3 times for every crankshaft rotation (6 divided by 2).
Multiply the engine rpm where the vibration condition occurs by the number of times the accessory
pulley is rotating per crankshaft revolution. For example, if the engine rpm is 2,400 rpm, the
accessory is rotating at 7,200 rpm (2,400 rpm multiplied by 3).
Divide the accessory rpm by 60 (the number of seconds in a minute). In this example, the engine
accessory frequency is 120 Hz (7,200 divided by 60).
Calculating Engine Firing Frequency

Engine firing frequency is a term used to describe the pulses an engine creates from the firing of the cylinders.
Engine firing frequency depends on how many cylinders an engine has. The number of times an engine fires a
cylinder with each crankshaft revolution is equal to one-half the number of cylinders. A 4-cylinder engine
fires 2 cylinders with each crankshaft revolution. Two revolutions of the crankshaft fire all 4 cylinders. A
6-cylinder engine fires 3 cylinders with each crankshaft revolution. An 8-cylinder engine fires 4 cylinders for
each crankshaft revolution.
Calculate engine firing frequency by performing the following steps:
Multiply the engine rpm where the vibration symptom occurs by the number of cylinders fired with
each crankshaft revolution. For example, a vehicle with a 6-cylinder engine experiences a vibration
concern at 2,400 rpm. The engine is firing the cylinders at 7,200 times per minute (3 multiplied by
2,400).
Divide this number by 60 (the number of seconds in a minute) to obtain the engine firing frequency.
In this example, the engine firing frequency is 120 Hz (7,200 divided by 60) at 2,400 rpm.
Frequency and RPM Calculations Worksheet
Harshness Symptoms
Harshness is customer perception which gives the impression of no isolation from the tire/wheel and
suspension system. Harshness may be caused by road conditions, temperature changes, component damage
and/or incorrect customer modifications on original components/specifications. Customers usually experience
harshness when the vehicle is driving over bumps or potholes and in cold weather conditions. Harshness can
also be experienced with excessive tire pressure, sporty tires, heavy-duty springs and shocks, or other vehicle
modifications. Some aftermarket tires, even with the correct size, may change vehicle behavior and produce

customer concerns. The first step in diagnosing a harshness concern is to determine if the concern was
experienced only in certain specific operating conditions, such as large potholes or extremely cold weather. In
these cases, harshness should be considered normal. A known good vehicle can be driven under the same
conditions and the rides can be compared to determine whether the concern is normal or vehicle specific. The
second step is to check tire pressure and make sure it was set within vehicle specifications. The third step is to
inspect for aftermarket or modified components and determine if they are the cause of the harshness
complaint. If the harshness concern persists after the above steps, it is possible that some components are
damaged. Based on the results from the road test, make a determination of which action in the symptom chart
to take first.
NVH Symptom Chart Categories
A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. Use
the symptom and possible system categories as follows:
Identify the operating condition that the vehicle is exhibiting.

Match the operating condition to the symptom.
Verify the symptom.
Calculate the frequency and order of the symptom.
Identify which category or system(s) could cause the symptom.
Refer to the section indicated to identify and diagnose the symptom or confirm that the system is not
the source of the condition.
Use the diagnostic instructions in this section along with the necessary listed tools to identify the vibration
order and to isolate the symptom and the possible systems associated with that symptom. Then based on the
results from the road test, make a determination of which action in the symptom chart to take first. Since it is
possible any one of multiple systems may be the cause of the symptom, it may be necessary to use a process
of elimination type diagnostic approach to pinpoint the concern. Refer to the section(s) indicated to identify
and isolate the cause or rule that system out as being the causal system for the symptom.
Symptom Chart - Vehicle-Speed Related Vibrations
NOTE: Any assembly that is out of balance will only cause a first order vibration, it will not cause a higher
order vibration.
When a vehicle-speed related vibration is present, both tire-speed related vibration and driveshaft-speed
related vibration calculations should be carried out.
Symptom Chart - Tire-Speed Related Vibrations
Symptom Chart - Tire-Speed Related Vibrations
Symptom Chart - Driveshaft-Speed Related Vibrations
Symptom Chart - Driveshaft-Speed Related Vibrations

order vibration.
ConditionPossible SourcesAction
First order driveshaft vibration

Driveshaft
REFER to Section 205-00 .
Pinion gear
Pinion bearing
Second order driveshaft vibration
U-joint
Output shaft bushing in transmission/transaxle
REFER to Section 308-07A . Refer to the appropriate section in Group 307 for the procedure.
Third order driveshaft vibration
Axle shaft
Ring gear
Symptom Chart - Engine-Speed Related Vibrations
Symptom Chart - Engine-Speed Related Vibrations

NOTE: When an engine-speed related vibration is present, engine, engine accessory and engine firing
calculations should be carried out.
order vibration.
NOTE: Some engine-speed related vibrations are normal though they should not be felt in the passenger
compartment.
0.5 order engine vibration
Engine
First through sixth order engine vibration

Engine
Transmission/transaxle
Engine mounts
Transmission/transaxle mounts
Exhaust system
Belt driven accessory speed vibration
Engine pulley
Coolant pump
Generator
A/C compressor
Power steering pump
Vacuum pump
Accessory drive belt
Symptom Chart - Noise, Air Leaks or Water Leaks
Symptom Chart - Noise, Air Leaks or Water Leaks

Symptom Chart - Harshness
Symptom Chart - Harshness

SECTION 501-00: Body System - General Information 2011 Expedition, Navigator Workshop Manual
SPECIFICATIONS Procedure revision date: 08/12/2010
Material
Item Specification Fill Capacity

3MTM Strip Caulk - Black WSB-M4G32-C -
051135-08578
Seam Sealer - -
TA-2
Clear Silicone Rubber ESB-M4G92-A -
TA-32
WSE-M4G323-A4 -
Silicone Spray Lubricant ESR-M13P4-A -
XL-6
Trim and Weatherstrip Adhesive - -
TA-14-A

2011 Expedition, Navigator Workshop

SECTION 501-00: Body System - General Information
Manual
Insulation
Insulation is used as a sound-deadener to reduce exterior road and powertrain noises from the interior of the
vehicle. Mastic insulators are also used as insulation. For information on the location of the mastic insulators,
refer to Section 501-35 . Insulation is installed:
under the roof.

above and below the instrument panel.
at the cowl sides.
over the transmission tunnel.
over the floorpan areas.
inside the quarter panels.
It has heat-bondable mastic deadeners for improved NVH characteristics (Navigator).
Insulation 79

SECTION 501-00: Body System - General Information
Manual
Body Sealer Types And Applications
Seam Sealer
Seam Sealer TA-2 or equivalent:
is a heavy-bodied, non-sag adhesive/sealer for use on standing cosmetic seams, truck bed seams,
tooled door skin seams and floor pans.
can be used on water leaks and noise concerns.
Clear Silicone Rubber
Clear Silicone Rubber TA-32 or equivalent meeting Ford Specification ESB-M4G92-A:
does not r.
is fast drying.
remains semi-elastic.
can be used for sealing water leaks, noise concerns, remounting trim and repairing torn
weatherstripping.
Silicone Gasket and Sealant
Silicone Gasket and Sealant TA-30 or equivalent meeting Ford specification WSE-M4G323-A4:
is a form-in-place gasket and multi-purpose adhesive/sealant.

is a room temperature curing silicone rubber.
Caulking Cord
3MTM Strip Caulk-Black 051135-08578 or equivalent meeting Ford specification WSB-M4G32-C:
is a heavy-bodied, plastic base with a filler.

is commonly known as perma-gum.
is used on spot-weld holes and between surfaces not sealed with a gasket.
Weatherstrip Adhesive
Trim and Weatherstrip Adhesive TA-14-A or equivalent:
is a quick drying, strong adhesive designed to hold weatherstripping onto all body panels and
surrounding metal.
Silicone Lubricant
Silicone Spray Lubricant XL-6 or equivalent meeting Ford specification ESR-M13P4-A:
is used to keep the door and the window weatherstrip pliable and soft.
makes the door easier to close.
retards weatherstrip squeaks.
retards weatherstrip wear.
Body Sealer Types And Applications 80

helps retain door window alignment by reducing friction between the glass frame and the rubber
weatherstrip.
should not be used prior to painting.
Body Sealer Types And Applications 81

SECTION 501-00: Body System - General Information 2011 Expedition, Navigator Workshop Manual
Body System
Material
Item Specification
3MTM Strip Caulk - Black WSB-M4G32-C
051135-08578
Clear Silicone Rubber ESB-M4G92-A
TA-32
Seam Sealer -
TA-2
Silicone Gasket and Sealant WSE-M4G323-A4
TA-30
Silicone Spray Lubricant ESR-M13P4-A
XL-6
Trim and Weatherstrip Adhesive -
TA-14-A
Inspection and Verification
Dust and Water Leaks
Most dust and water leaks occur due to missing or mis-installed body sealer or components. The source of the
leak is detected by:
pressurizing the vehicle and testingpy water.

Locate and tape off the body vents.
Turn the blower motor on the high position.
Turn the air recurculation to the off mode.
Close the windows and doors.
Open the hood and spray soapy water along body seams and grommets. Make sure to test the
areas arround the A-pillar at the fender and the hood hinge area.
Check for bubbles.
inspecting for a dust pattern or water path near and above the area in question.
removing any trim or carpet in the general area of the leak.
road testing or water-hose testing the vehicle.
placing a bright light under the vehicle, removing any necessary trim or carpet and inspecting the
interior of the body at joints and weld lines.
Wind Noise
Most wind noise leaks occur at the corners of the windows or in the doors. Wind noise is detected by driving
the vehicle at highway speeds or at speeds as specified by the customer. The vehicle should be driven in 4
different directions, with all the windows CLOSED, the radio OFF and the A/C blower motor OFF.
Squeak and Rattle
Body System 82
Squeak and rattle noises are generally caused by loose parts, contact or relative movement between 2 surfaces
or loose wires and connectors. The source of the noise can be detected by stopping movement of the suspect
part by hand or by using dampening or low friction materials.
Symptom Chart - NVH
Symptom Chart - NVH

NOTE: NVH symptoms should be identified using the diagnostic tools that are available. For a list of these
tools, an explanation of their uses and a glossary of common terms, refer to Section 100-04 . Since it is
possible that any one of multiple systems may be the cause of a symptom, it may be necessary to use a process
of elimination type of diagnostic approach to pinpoint the responsible system. If this is not the causal system
for the symptom, refer back to Section 100-04 for the next likely system and continue diagnosis.
Draft/wind noise and water leak around door perimeter
Loose fit seal
PINCH seal carrier to improve retention on seal flange.
Seal installed incorrectly
REINSTALL the seal.
Door misaligned
REALIGN the door. CHECK door gaps and fit in door opening and ADJUST as necessary. REFER to
Section 501-03 .
Scuff plate installed incorrectly
REINSTALL the scuff plate.
Seal or seal pushpins damaged
INSTALL a new seal/pushpins.
Sheet metal joints in door or door opening
SEAL leaks with silicone gasket and sealant.
Draft/wind noise and water leak around glass run
Door glass misaligned
ADJUST door glass.
Glass run installed incorrectly
REINSTALL glass run. INSERT foam in glass run carrier if necessary.
Leak path behind glass run
Body System 83
INSTALL foam rope behind glass run.
Glass run channel spread wide
PINCH glass run channel to reduce size of opening.
Glass run damaged
INSTALL a new glass run.
Draft/wind noise and water leak at inner belt line
Belt line seal installed incorrectly on flange
ADJUST seal. (Do not bend the flange.)
No contact with side glass
ADJUST door glass.
No contact with glass runs at both ends of belt line seal
ADJUST belt line seal or ADD foam at seal ends.
Belt line seal damaged
INSTALL a new seal.
Draft/wind noise and water leak at outer belt line
Belt line seal installed incorrectly on flange (no glass contact)
ADJUST seal.
Belt line seal does not contact the glass
ADJUST door glass.
No contact with glass runs at both ends of belt line seal
ADJUST belt line seal or ADD foam at seal ends.
Belt line seal damaged
INSTALL a new seal.
Draft/wind noise at inner door handle/speaker opening
Hole in weathershield
SEAL hole with suitable tape.
Weathershield misaligned
Body System 84
REALIGN weathershield. INSTALL a new weathershield if pressure sensitive adhesive fails.
Exterior door handle seal misaligned/damaged
REALIGN or INSTALL a new seal as necessary. REFER to Section 501-14 .
Speaker or speaker seal missing or damaged
REPAIR speaker seal or INSTALL a new door speaker.
Draft/wind noise and water leaks at floor pan and grommets
Missing or damaged plugs/grommets
CHECK plugs/grommets for correct installation or damage. INSTALL new plugs/grommets if

necessary.
Road noise
Missing mastic insulators
CHECK for missing mastic insulators. REFER to Section 501-35 .
Missing body insulators
CHECK for missing body insulators.
Rattles in body/doors and instrument panel
Loose wires/cables
CHECK that all wires/cables are correctly routed and inserted in correct retainers.
Loose objects/components in door wells, pillars quarter trim panels
CHECK doors by carefully striking underside of doors with a rubber mallet while listening for rattles
in doors and pillars. REMOVE or TIGHTEN loose objects/components.
Buzz from instrument panel components
IDENTIFY which components of the instrument panel are buzzing. SECURE/FASTEN components
as necessary, ADD foam or felt as needed if rattle persists.
Door drain holes collecting water
Holes clogged with mud or road tar
CLEAN drain holes of foreign material with a punch or screwdriver. CHECK drain holes regularly.
Wind noise from exterior rear view mirror
Exterior mirror housing misaligned
REALIGN with edges shingled to airflow, with no gaps.
Body System 85
Mirror sail gasket folded/misaligned
REINSTALL with gasket unfolded and aligned correctly.
Mirror housing trim cap installed incorrectly
REINSTALL with edges shingled to airflow.
Air leak through mirror housing hinge
Fully ENGAGE mirror into its operating position. USE foam to block air path through hinge.
Inner sail trim installed incorrectly
REINSTALL sail trim. ADJUST door trim.
Inner sail gasket/barrier installed incorrectly
REINSTALL trim cover with gasket/barrier aligned correctly.
Air path through wiring bundle/fastener access holes
BLOCK air path(s) with foam/tape.
Exposed fastener access hole on mirror housing/sail
INSTALL a new cap if missing.
Rattle/vibration from exterior rear view mirror
Mirror glass adjustment screws loose
REMOVE mirror glass and TIGHTEN mirror glass adjustment motor screws. REFER to Section
501-09 .
Mirror mounting nuts loose
TIGHTEN mirror mounting nuts. REFER to Section 501-09 .
Aftermarket air deflector/stone shields
If possible, REMOVE aftermarket air deflector/stone shield, then ROAD TEST vehicle. If concern is
no longer present, ADVISE customer that aftermarket component was causing concern.
If equipped with power fold mirrors, power fold mirrors folded/unfolded manually or are not
synchronized
If equipped with power fold mirrors, SYNCHRONIZE power fold mirrors. REFER to Section 501-09
.
Draft/wind noise and water leak around perimeter of all fixed glass
Gaps in the sealant bead
Body System 86
APPLY approved sealant.
Air traveling up windshield molding along A-pillar
INSTALL foam rope full length of the A-pillar.
Gaps in sealant bead of windshield/rear glass
RESEAL windshield/rear glass. REFER to Section 501-11 .
Windshield glass misaligned or not installed correctly
REINSTALL windshield glass. REFER to Section 501-11 .
Rear hood seal at base of windshield misaligned/damaged
REALIGN or INSTALL a new seal as necessary.
Draft noise at cowl
Cowl seal misaligned/damaged
REALIGN or INSTALL a new seal as necessary.
Draft/wind noise and water leak around liftgate perimeter
Loose fit seal
PINCH seal carrier to improve retention on seal flange or INSERT foam in carrier.
Seal misaligned or installed incorrectly
REINSTALL seal.
Liftgate misaligned
REALIGN liftgate. CHECK liftgate fit in body opening and ADJUST as necessary.
Scuff plate misaligned
REINSTALL scuff plate.
Seal or seal pushpins damaged
INSTALL a new seal.
Draft/wind noise and water leak around perimeter of rear quarter flip window glass
Loose fit seal
PINCH seal carrier to improve retention on seal flange or INSERT foam in carrier.
Seal misaligned or installed incorrectly
Body System 87
REINSTALL seal.
Glass misaligned
REALIGN glass.
Seal damaged
INSTALL a new seal.
Draft/water leak or noise from roof opening panel
Roof opening panel/components
REFER to Section 501-17 for diagnosis.
Wind noise created by airflow over or behind body panels
Fender splash shield misaligned
REALIGN fender splash shield.
Body panel misaligned (exposed edge)
REALIGN appropriate body panel.
Hood misaligned (front margin)
CHECK hood gaps and fit. ADJUST hood as necessary.
Front grille edge noise
APPLY foam in hollow areas behind louvers.
Wind noise created by grille opening panel
Grille relationship to leading edge on hood
If possible, ADJUST grille opening panel forward to eliminate wind noise.
Sharp edges due to material imperfections
REMOVE sharp edges (no damage to visible surface).
Wind noise from air extractor (body vent)
Air extractor housing seated incorrectly
REINSTALL air extractor housing.
Air extractor housing or flaps damaged
INSTALL a new air extractor.
Body System 88
Noise from roof rack
Roof rack rails or crossbars loose
TIGHTEN fasteners.
Roof rack fasteners missing
INSTALL approved fasteners.
Roof rack crossbars installed backward
REINSTALL crossbars.
Roof rack rub strips partially lifting from roof
REAPPLY adhesive or fasteners or INSTALL new rub strips as necessary.
Roof rack gaskets loose or misaligned
REINSTALL gasket.
Wind noise from bug shield/exterior windshield sun visor
Turbulence created by location and shape
DETERMINE if an OEM part or aftermarket. If aftermarket advise customer accordingly. If OEM,

VERIFY correctly installed. If noise is abnormal REPAIR or INSTALL new as required.
Body System 89
SECTION 501-02: Front End Body Panels 2011 Expedition, Navigator Workshop Manual
Torque Specifications
Description Nm lb-ft lb-in

Coolant module bolt 15 - 133
Electrical junction box bolt 35 26 -
Fender splash shield screws 3 - 27
Fender-to-front radiator support bolts 12 - 106
Front bumper cover-to-fender bolts 11 - 97
Headlamp bolts 3 - 27
Hood hinge-to-body bolts 30 22 -
Hood hinge-to-hood bolts 30 22 -
Hood latch bolt 35 26 -
Hood striker bolts 12 - 106
Horn assembly bolt 35 26 -
Lower fender boltp" align="center">12 - 106
Radiator grille support bolt 35 26 -
Upper fender bolts 12 - 106
Wiper pivot arm nut 35 26 -
Body System 90
GENERAL PROCEDURES Procedure revision date: 08/12/2010
Hood Alignment
1. Raise and support the hood.
2. Loosen the 2 hood hinge-to-hood bolts enough to hold the hood in place.
3. NOTE: Repeat Steps 2 and 3 until satisfactory alignment is achieved.
Align the hood. For additional information, refer to Section 501-35 .
4. When correctly aligned, tighten the hood hinge-to-hood bolts to 30 Nm (22 lb-ft).
Hood Alignment 91
REMOVAL AND INSTALLATION Procedure revision date: 08/12/2010
Front End Body Panels - Exploded View
NOTE: Navigator shown, Expedition similar.
Item Part Number Description

1 W713375 Fender splash shield screws (8 required)
2 W708035 Pin-type retainers (3 required)
3 16045 LH/ 16044 RH Fender splash shield
4 W712923 Front bumper cover-to-fender bolts (2
required)
5 W712923 Fender-to-radiator support bolt
6 N807658 Lower fender bolt (2 required)
7 W505425 Headlamp bolt (2 required)
8 13A006 Headlamp electrical connector
9 13008 Headlamp
10 W712923 Upper fender bolt (4 required)
11 16005A RH/ 16005B Fender
LH
1. For additional information, refer to the procedures in this section.
Front End Body Panels - Exploded View 92

Front End Body Panels - Exploded View 93

Fender Splash Shield
Vehicles with power running boards
1. Lower the running board.
2. WARNING: Turn off (disable) the power running boards (if equipped) before jacking,
lifting or placing any object under the vehicle.
Never place your hand between the power running board and the vehicle. Extended power
running boards will retract when doors are closed.
With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .
All vehicles
3. Remove the lower pin-type retainer from the fender.
4. Remove the 8 fender splash shield screws.
5. Remove the 2 inner pin-type retainers from the fender splash shield.
6. Remove the fender splash shield.
7. To install, reverse the removal procedure.
Fender Splash Shield 94

Fender
Removal and Installation
1. Remove the fender splash shield. For additional information, refer to Fender Splash Shield in this
section.
2. Remove the 2 front bumper cover-to-fender bolts.

To install, tighten to 11 Nm (97 lb-in).
3. Remove the fender-to-radiator support bolt.

4. Remove the 2 lower fender bolts.

5. Remove the headlamp.

Remove the 2 headlamp bolts.
Disconnect the electrical connectors.
6. Remove the cowl panel grille. For additional information, refer to Cowl Panel Grille in this section.
7. Remove the 4 upper fender bolts and remove the fender.

Fender 95
Cowl Panel Grille

1 17526 Wiper pivot arm (LH and RH)
2 W707014 Wiper pivot arm nut (2 required)
3 388577 Pin-type retainers (2 required)
4 78022A68AA Cowl panel RH
5 78022A69AA Cowl panel LH
Both sides
1. Remove the windshield wipers. For additional information, refer to Section 501-16 .
LH side
2. Remove the pin-type retainer and lift the LH cowl trim panel to release the 3 underside pushpin
retainers that are attached to the cowl trim panel.
Disconnect the windshield washer tube.
RH side
3. Remove the pin-type retainer and lift the RH cowl trim panel to release the 2 underside pushpin
retainers that are attached to the cowl trim panel.
Disconnect the windshield washer tube.
Both sides
Cowl Panel Grille 96

5. If necessary, adjust the windshield wiper arms. For additional information, refer to Section 501-16 .
Cowl Panel Grille 97

Radiator Grille Support

1 16138A Radiator grille support
2 W710835 Radiator grille support bolts (6 required)
3 14A465 Electrical junction box bracket
4 W711851 Electrical junction box bolt (4 required)
5 W711848 Horn assembly bolt
6 16700 Hood latch
7 W711848 Hood latch bolt (2 required)
8 16916 Hood latch cable
9 W712310 Hood latch cable retainer
10 W710309 Coolant module bolt (2 required)
1. Remove the front bumper cover. For additional information, refer to Section 501-19 .
2. Remove the headlamp bolts. For additional information, refer to Section 417-01 .
3. Disconnect the battery. For additional information, refer to Section 414-01 .
4. Remove the 4 electrical junction box bolts.

To install, tighten to 35 Nm (26 lb-ft).
Radiator Grille Support 98

5. Disconnect the ambient air temperature sensor retaining clip and position the sensor and harness
aside.
6. Disconnect the horn assembly electrical connector and remove the horn assemble bracket bolt.
7. Disconnect the hood latch cable retainers, remove the hood latch assembly bolts and position the latch
assembly and cable aside.
8. Remove the LH and RH coolant module bolts.


9. Remove the 6 radiator grille support bolts (3 each side).

10. Remove the radiator grille support.
11. NOTICE: Inspect and transfer all of the radiator grille support isolators. Replace as necessary.
NOTE: Transfer all necessary components.
To install, reverse the removal procedure.

SECTION 501-03: Body Closures 2011 Expedition, Navigator Workshop Manual

Material

Threadlock 262 WSK-M2G351-A6 -
TA-26

Door/liftgate striker 25 18 -
Front door hinge-to-body bolts 30 22 -
Front door hinge-to-front door bolts 30 22 -
Liftgate hinge-to-body bolts 30 22 -
Liftgate hinge-to-body nuts 23 17 -
Liftgate hinge-to-liftgate bolts 28 21 -
Liftgate motor fasteners 11 - 97
Liftgate rod mounting stud 48 35 -
Liftgate rod-to-liftgate retaining nut 11 op" align="center">- 97
Liftgate strut-to-body ball stud 25 18 -
Liftgate strut-to-liftgate ball stud 25 18 -
Liftgate/Trunk Module (LTM) bolt 9 - 80
Power liftgate rod bracket-to-pillar bolts 13 - 115
Power liftgate rod-to-bracket bolt 30 22 -
Rear door hinge-to-B-pillar nuts 30 22 -
Rear door hinge-to-rear door bolts 30 22 -



Body Closures
The power liftgate feature allows the customer to automatically open or close the liftgate by: activating the
instrument panel control button, activating the Remote Keyless Entry (RKE) transmitter, lifting the exterior
handle (open only) or activating the rear quarter trim-mounted switch (close only). The power liftgate feature
uses a power cinching system to latch the liftgate.
Power liftgate operation requires the vehicle to be in PARK and the vehicle speed to be less than 5 km/h (3
mph).
The power liftgate feature suspends a power open or power close when the ignition key is moved to the
START position. The clutch will remain active to hold the liftgate in place during a start operation. Once the
ignition key is no longer in the START position, the liftgate power open or power close will resume. If the
ignition key is cycled during a power close and the liftgate is 15 cm to 24 cm (6 in to 10 in) from being
latched, the liftgate may reverse to the full open position.
The power liftgate feature can be enabled/disabled from the message center. When the power liftgate feature
is disabled (OFF), operation from the liftgate handle and liftgate rear control switch are disabled.
To manually open the power liftgate, due to power latch loss of function, remove the latch access cover
located on the lower center of the liftgate trim panel. Reach in at the center of the latch assembly and push the
manual latch release lever to the right on the latch assembly.
The power liftgate system consists of the following components:
Power liftgate control switch (located in the instrument panel)

Power liftgate rear control switch (located in the LH rear quarter trim panel)
Exterior handle switch
Power liftgate motor (located behind the LH rear quarter trim panel)
Power liftgate clutch (part of the liftgate motor)
Power liftgate rod (attached to the power liftgate motor assembly and liftgate mounting stud)
Position sensor (located in the power liftgate motor assembly)
Pinch strip switches (located on the body above the left and right tail lamps)
Power liftgate latch (located in the middle lower portion of the liftgate)
Forkbolt switches (located in the power liftgate latch)
Sector gear switches (located in the power liftgate latch)
Detent switch (located in the power liftgate latch)
Unlatch/cinching motor (located in the power liftgate latch)
Liftgate/Trunk Module (LTM) (located behind the left rear quarter trim panel)
The power liftgate is controlled by the LTM .
The LTM receives inputs from the following:
Forkbolt switch - primary (determines the position of the latch)

Forkbolt switch - secondary (determines the position of the latch)
Sector gear open switch - open (determines the sector gear position)
Sector gear close switch - close (determines the sector gear position)
Smart Junction Box (SJB) (exterior handle)
Detent switch (determines the position of the latch)
Power liftgate control switch (located in the instrument panel)
Body Closures 103

Power liftgate rear control switch (located in the LH rear quarter trim panel)
Pinch strip switches (determines if an obstacle is between the pinch strip and liftgate)
Position sensor (determines the direction, travel speed and obstacle detection of the liftgate)
Controller Area Network (CAN) serial communication link
The LTM sends outputs to the following:
Liftgate motor
Liftgate clutch
Unlatch/cinching motor
Liftgate chime
SJB (ajar status)
The liftgate chime sounds an audible chime (located on the power liftgate motor assembly) for 3 seconds
whenever a powered closing operation is initiated or if conditions are not correct for closing. The chime sound
serves as a warning to alert the vehicle occupants and any bystanders that the liftgate is being moved in a
closing direction by a powered operation. The gate will not be moved for the first second, as a pre-warning of
impending gate movement.
The power liftgate may not operate under the following conditions:
Low voltage or dead battery

Disconnected battery
Power liftgate that has been manually closed and left ajar
If any of these conditions have occurred, the power liftgate must be reinitialized before carrying out
any pinpoint tests. Refer to Power Liftgate Initialization in this section.
Body Closures 104


Power Liftgate
Special Tool(s)
Flex Probe Kit

105-R025D or equivalent
Fluke 77-IV Digital Multimeter

FLU77-4 or equivalent
Vehicle Communication Module (VCM)

and Integrated Diagnostic System (IDS)
software with appropriate hardware, or
equivalent scan tool
Principles Of Operation
Power and Ground Requirements
NOTE: The Smart Junction Box (SJB) may also be identified as the Generic Electronic Module (GEM).
SJB fuse 14 (10A) supplies battery logic power required for the software, clutch and internal switching
operations. Power is supplied to the motor by Battery Junction Box (BJB) fuse 36 (30A).
Ground for the Liftgate/Trunk Module (LTM) is a separate single connection. Some of the continuous inputs
which are at a ground state when on are also used for logic switching.
Power Liftgate Detent Switch, Forkbolt Primary Switch and Forkbolt Secondary Switch
The power liftgate detent switch, forkbolt primary switch and forkbolt secondary switch provide inputs to the
LTM in order to determine liftgate latch position. The LTM receives inputs from the power liftgate detent
switch, forkbolt primary switch and forkbolt secondary switch in the following manner:
NOTE: The liftgate is in the primary position when the liftgate is in the full closed position. The liftgate is in
the unlatch position when the liftgate is open and completely out of the striker. The liftgate can be placed in
the unlatched position by lifting up on the liftgate handle.
Latch Switch States
Latch Position Detent Switch Forkbolt Secondary Switch Forkbolt Primary Switch
Fully Unlatched Open a Grounded Grounded
In Secondary Grounded a Open Grounded
In Primary Grounded Open Open
Power Liftgate 105

aThe detent switch may be in open or grounded state depending on forkbolt position. The detent switch state
changes as the forkbolt rotates.
Manual Latch Release for Power Liftgate
To manually open the power liftgate, due to power latch failure, remove the latch access cover located on the
lower center of the liftgate trim panel. Reach in on the right side of the opening, and push down on the manual
latch release lever.
Unlatch/Cinching Motor
The latch uses a bi-directional motor to accomplish both release and cinch operations. The motor is driven in
one direction to cinch and in the opposite direction to release.
During a cinch operation, power is supplied to the unlatch/cinching motor by the LTM when the secondary
latch position is reached during a power close operation. When the motor activates, it pulls the liftgate into the
primary latch position. The LTM removes power from the unlatch/cinching motor when the primary latch
position is reached.
During an unlatch operation, power is supplied to the unlatch/cinching motor by the LTM when a valid open
command is received.
Sector Gear Switches
The sector gear open switch and sector gear close switch provide input to the LTM in order to determine the
position of the sector gear. The sector gear is part of the latch assembly. It is driven by the latch motor and in
turn drives the latch mechanism. During a release operation, the LTM deactivates the unlatch/cinching motor
once the end of travel is reached. After a release operation, the LTM keeps the latch released until the gate
moves away from the vehicle. The LTM then reverses the direction of the unlatch/cinching motor until the
sector gear switches indicate the sector gear has returned to the neutral position. Refer to the following table
for sector gear switch states:
Sector Gear Switch States
Sector Gear Position Sector Gear Open Switch Sector Gear Close Switch
End of Travel Grounded Grounded
Release Open Grounded
Cinch Grounded Open
Neutral Open Open
The drive assembly consists of the following:
Position Sensor
When awake, the LTM supplies a 5-volt reference voltage to the position sensor on a valid open command or
anytime the liftgate is in the open position (up to 6 hours). The LTM constantly supplies the ground. The
position sensor has 2 data lines that the LTM monitors to determine the liftgate movement and position. The
LTM uses the liftgate position information to determine which direction to power the liftgate (open or close)
when a valid operation command is received. The movement is monitored to identify obstructions.
Position Sensor 106

Actuator Clutch
The drive assembly actuator clutch separates the drive assembly actuator motor from the liftgate drive gear.
This allows manual opening and closing of the liftgate without driving the motor. The LTM supplies power to
the drive assembly actuator clutch for any valid open/close operation. The clutch connects the drive assembly
actuator motor to the drive actuator, allowing the motor to turn the actuator and open or close the liftgate.
Actuator Motor
The drive assembly actuator motor is a reversible motor. Upon a valid activation, the LTM supplies power
and ground to the motor circuits depending on the liftgate position and the direction the liftgate needs to be
moved.
Power Liftgate Control Switch Instrument Panel
Pressing the instrument panel power liftgate control switch supplies a momentary ground signal to the LTM
which will open or close the liftgate depending on the conditions.
Power Liftgate Rear Control Switch Quarter Trim Panel
Pressing the power liftgate rear control switch (located on the LH quarter trim panel) supplies a momentary
ground signal to the LTM which will close the liftgate depending on the conditions.
Exterior Handle Switch
When the exterior handle switch is activated, the SJB sends a signal to the LTM which will open the liftgate
depending on the conditions.
Remote Keyless Entry (RKE) Operation
The SJB receives a power liftgate activation command (double press) from the Remote Keyless Entry (RKE)
transmitter. The SJB will send a signal on the Controller Area Network (CAN) to the power liftgate. The
signal transmitted between the SJB and the LTM is not specific to the open or close operation. The LTM will
determine which operation to carry out depending on the liftgate position when the signal is received.
Power Liftgate Interface
Power liftgate open operation requires the vehicle to be in PARK and the vehicle speed to be less than 5 km/h
(3 mph). The power liftgate receives information over the CAN from the PCM for the PRNDL position and
from the Instrument Cluster (IC) (gateway) for vehicle speed. These inputs have network DTCs. If any vehicle
speed or transmission rangeTransmission Range (TR) switch DTCs are retrieved and the power liftgate is not
operating, repair these DTCs first.
Power Liftgate Operation
The following is a brief explanation of a normal power open cycle of the power liftgate.
The power open operation will begin with one of the following methods:
The LTM receives a momentary ground signal from the power liftgate control switch.
The SJB receives a signal from the remote transmitter key fob (double button press).
The LTM receives a signal from the SJB indicating the exterior liftgate handle has been
activated.
The LTM checks the PRNDL position and vehicle speed status from the CAN communication link.
The LTM supplies power to the unlatch/cinching motor until the sector gear switches indicate end of
travel which releases the power liftgate latch.
Actuator Clutch 107

The power liftgate detent switch, primary forkbolt switch and secondary forkbolt switch circuits are
monitored for correct latch release signals.
Power is supplied to the drive assembly actuator clutch and motor, opening the power liftgate.
The power liftgate supplies power to the unlatch/cinching motor while monitoring the sector gear
switches to return the sector gear to the neutral position.
When the power liftgate is opening, the position sensor is monitored for liftgate position and velocity.
If an obstruction is detected, the liftgate will stop.
The power liftgate full open position is learned by the LTM during the power liftgate initialization.
When the power liftgate reaches the full open position, the LTM removes the power from the drive
assembly actuator motor and clutch.
After the power is removed from the clutch and drive motor, the position sensor briefly continues to
monitor the position of the liftgate. If excessive movement in the closed direction is detected, power is
reapplied to the clutch and a continuous chime is initiated and remains on as the liftgate is
automatically power closed.
If the excessive closing movement is detected on 11 successive power open requests, DTC B201A is
set and power liftgate operation is disabled until the DTC is cleared.
The following is a brief explanation of a normal power close cycle of the power liftgate.
The power close operation will begin with one of the following methods:
The LTM receives a momentary ground signal from the power liftgate control switch.
The LTM receives a momentary ground signal from the power liftgate rear control switch
(LH rear quarter panel).
The SJB receives a signal from the remote transmitter key fob (double press).
The LTM checks the PRNDL position and vehicle speed status from the CAN communication link.
The LTM will start an audible chime.
After one second of audible chime, power is supplied to the drive assembly actuator clutch and motor
as the audible chime continues 3 seconds total.
As the power liftgate is powered closed, the position sensor is monitored for liftgate position and
velocity. The power liftgate will reverse if an obstruction is detected.
Also, as the power liftgate is powered closed, the pinch strips are monitored for a pinch condition.
The power liftgate will reverse if an obstruction is detected by either pinch strip.
The power liftgate detent switch, forkbolt primary switch and forkbolt secondary switch circuits are
monitored for correct latch signals.
When the LTM receives switch signals indicating the secondary latch position is reached, power is
supplied to the unlatch/cinching motor to pull the liftgate into the primary latch position. When
primary latch position is reached, power is removed from the drive motor and clutch.
When the LTM receives switch signals indicating the primary latch position has been reached (liftgate
is fully closed), the LTM reverses the direction of the unlatch/cinching motor until the sector gear
switches indicate the neutral position.
Power Liftgate Chime
The LTM requests a chime to sound for 3 seconds when:
the LTM receives a request to power close.

the liftgate reverses when closing due to an obstacle.
the liftgate stops opening due to an obstacle.
The LTM requests a chime to sound for one second when an open or close input is received when:
the vehicle speed is greater than or equal to 5 km/h (3 mph).

the ignition key is in the RUN position and the transmission is not in the PARK position.
the battery voltage is between 8 and 9.5 volts.
Actuator Motor 108

The LTM requests a continuous chime during a power close immediately after a power open under the
following conditions:
there is excessive weight on the liftgate (snow, ice, bicycle rack).

worn/damaged liftgate assist cylinders.
the LTM incorrectly learned the full open position during the power liftgate initialization procedure.
The chime will sound continuously for up to 5 minutes when the transmission is shifted out of the PARK
position or the vehicle speed exceeds 5 km/h (3 mph) while the liftgate is open/ajar. The chime will stop
sounding when the liftgate reaches the latch, 5 minutes has elapsed or the transmission is shifted into the
PARK position and the vehicle speed is less than 5 km/h (3 mph).
The chime will sound continuously for up to 5 minutes when the liftgate fails to close to the primary latch
position after 20 seconds of powering in the close direction. The chime will stop if the liftgate reaches the
primary latch position or 5 minutes has elapsed.
Power Liftgate Initialization Procedure
If the LTM loses the logic battery supply for any reason, such as battery disconnect, module disconnect or if
left open for more than 6 hours, the LTM will lose the power liftgate position stored in memory and will
attempt to open when the liftgate switch is pressed the first time.
The power liftgate can also lose position if the following components are removed, adjusted or disconnected:
Power liftgate motor

Liftgate hinges
Power liftgate rod
Liftgate striker
The power liftgate normal operation will not be restored until the power liftgate position is once again stored
into memory. The initialization procedure is the learning process the LTM uses to restore the power liftgate
position in memory. The LTM monitors the position sensor data received during the initial power
open-and-close operation to learn the position.
Refer to Power Liftgate Initialization in this section.
Power Liftgate Awake/Sleep Status
The LTM is in the awake state whenever the ignition is in the RUN position.
The LTM is in the awake state while carrying out a close or an open operation, including cinch.
The LTM is in the sleep state when all of the following conditions exist:
The latch is not in the fully unlatched position.
The ignition is in the OFF position.
No power operation is active.
No wakeup inputs have changed state for more than 20 seconds.
The LTM is also in the sleep state when all of the following conditions exist:
The latch is in the unlatched position.
The ignition is in the OFF position.
No power operation is active.
No wakeup inputs have changed state for more than 6 hours.
The wakeup inputs for the power liftgate are:
Power liftgate open/close switch request signal
Actuator Motor 109

Forkbolt primary signal

Forkbolt secondary signal
Detent switch signal
Rear control switch
Exterior handle switch
Glass ajar switch
CAN
1. Verify the customer concern.
2. The battery voltage must be at normal operating levels in order for the power liftgate to open and
close correctly. Make sure the battery and charging systems are operating correctly before proceeding
with the power liftgate diagnosis.
3. Visually inspect for obvious signs of mechanical and electrical damage. Refer to the following chart.
Visual Inspection Chart
Mechanical Electrical
Power liftgate drive assembly Battery Junction Box (BJB) fuse 36

Power liftgate rod assembly (30A)
Power liftgate cinching latch Smart Junction Box (SJB) fuse(s):
Power liftgate pinch strip switches 14 (10A)
Liftgate and liftgate hinges 17 (20A)
Liftgate assist cylinders Circuitry
Liftgate strikers Power liftgate control switch
Exterior release handle instrument panel
Liftgate weatherstrip Power liftgate rear control switch
Liftgate alignment to body and striker quarter trim panel
Wedges Power liftgate position sensor
Excessive weight on the liftgate (for example: bike Power liftgate latch
rack or snow and ice) detent switch
primary forkbolt switch
secondary forkbolt switch
sector gear open switch
sector gear close switch
unlatch/cinching motor
Liftgate/Trunk Module (LTM)
SJB
4. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step.
5. NOTE: Make sure to use the latest scan tool software release.
If the cause is not visually evident, connect the scan tool to the Data Link Connector (DLC).
Actuator Motor 110

6. NOTE: The Vehicle Communication Module (VCM) LED prove out confirms power and ground
from the DLC are provided to the VCM .
If the scan tool does not communicate with the VCM :
check the VCM connection to the vehicle.

check the scan tool connection to the VCM .
refer to Section 418-00 , No Power To The Scan Tool, to diagnose no power to the scan tool.
7. If the scan tool does not communicate with the vehicle:

verify the ignition key is in the ON position.
verify the scan tool operation with a known good vehicle.
refer to Section 418-00 to diagnose no response from the Liftgate/Trunk Module (LTM) or
Smart Junction Box (SJB).
8. Carry out the network test.

If the scan tool responds with no communication for one or more modules, refer to Section
418-00 .
If the network test passes, retrieve and record Continuous Memory Diagnostic Trouble Codes
(CMDTCs).
9. NOTE: Carrying out the LTM initialization procedure will resolve concerns where the power liftgate
has lost position or was not initialized correctly. For information, refer to Power Liftgate Initialization
in this section.
Clear the CMDTCs and carry out the self-test diagnostics for the power liftgate or SJB .
10. If the DTCs retrieved are related to the concern, go to the Liftgate/Trunk Module (LTM) DTC Chart
or the Smart Junction Box (SJB) DTC Chart. For all other DTCs, refer to Section 419-10 .
11. If no DTCs related to the concern are retrieved, GO to Symptom Chart .
DTC Charts
Smart Junction Box (SJB) DTC Chart
DTC Description Action

B1331 Decklid Ajar Rear Door Circuit Failure REFER to Section 501-14 to diagnose the decklid
ajar circuit.
B2666 Liftgate Release Switch Circuit Failure REFER to Section 501-14 to diagnose the liftgate
handle release switch.
B273A Liftgate Release Output Circuit Short to GO to Pinpoint Test B .
Ground
B273B Liftgate Release Output Circuit Open or GO to Pinpoint Test B .
Short to Battery
All other REFER to the Master DTC Chart in Section 419-10
DTCs .
Actuator Motor 111

Liftgate/Trunk Module (LTM) DTC Chart

B106E Solid State Driver GO to Pinpoint Test A .
Disabled Due to Short
Circuit
B106F Module Disabled Due to VERIFY there is no short to ground in circuit CPR57 (GN/WH) or CPR58
External Fault (GN/OG). REPAIR circuit(s) as necessary. INSTALL a new
Liftgate/Trunk Module (LTM). REFER to Liftgate/Trunk Module (LTM)
in this section. TEST for normal operation.
B107D Obstacle Detected VERIFY obstacle is not present. CLEAR the DTCs. REPEAT the self-test.
While Closing If DTC B107D returns, GO to Pinpoint Test D .
B1105 Rear Open/Close GO to Pinpoint Test B .
Switch Active During
Self-Test
B1179 Latch Motor Circuit GO to Pinpoint Test A .
Short to Battery
B117A Latch Motor Circuit GO to Pinpoint Test A .
Short to Ground
B117B Latch Motor Circuit GO to Pinpoint Test A .
Open
B117C Latch Centering Switch If any other power liftgate related DTCs are present, DIAGNOSE those
Invalid first. If no other power liftgate DTCs are present, GO to Pinpoint Test I .
B1317 Battery Voltage High GO to Pinpoint Test J .
B1318 Battery Voltage Low GO to Pinpoint Test J .
B1342 ECU Is Faulted INSTALL a new LTM . REFER to Liftgate/Trunk Module (LTM) in this
section.
B2019 Liftgate Exceeded Time GO to Pinpoint Test C .
Allowed to Cinch Door
B201A Power System Disabled GO to Pinpoint Test K .
Due to High Manual
Closing Speed
B236A Chime Output Circuit GO to Pinpoint Test E .
Open
B2418 Sensor Power Short to GO to Pinpoint Test A .
Ground
B2419 Sensor 1 Invalid GO to Pinpoint Test A .
B2420 Sensor 2 Invalid GO to Pinpoint Test A .
B2552 Vbatt 2 Circuit Open GO to Pinpoint Test A .
B2699 Left Pinch Strip Open GO to Pinpoint Test G .
or Short to Battery
B2700 Right Pinch Strip Open GO to Pinpoint Test G .
or Short to Battery
B2701 Left Pinch Strip Stuck GO to Pinpoint Test G .
Active
B2702 Right Pinch Strip Stuck GO to Pinpoint Test G .
Active
B2703 Open/Close Switch GO to Pinpoint Test B .
Stuck Active
Actuator Motor 112

B2718 Liftgate/Decklid Ajar REFER to Section 417-02 to diagnose the liftgate/decklid ajar switch
Output Short to Battery circuit.
B2721 Liftgate/Decklid Ajar REFER to Section 417-02 to diagnose the liftgate/decklid ajar switch
Output Short to Ground circuit.
or Open
B2723 Glass Position Switch REFER to Section 417-02 to diagnose the liftgate glass ajar switch.
Active During Self-Test
B2819 Gate Motor Circuit GO to Pinpoint Test A .
Short to Battery
B2903 Chime Output Circuit GO to Pinpoint Test E .
Short to Battery
B2908 Latch Switch Invalid For an inoperative power liftgate, GO to Pinpoint Test A . For a power
liftgate that stops in secondary latch position, GO to Pinpoint Test C .
B2935 Drive Unit Failure GO to Pinpoint Test A .
B2936 Gate Motor Open GO to Pinpoint Test A .
B2937 Gate Motor Short to GO to Pinpoint Test A .
Ground
B2939 Gate Clutch Short to GO to Pinpoint Test A .
Ground or Open
B2940 Chime Output Circuit GO to Pinpoint Test E .
Short to Ground
U0140 Lost Communication REFER to Section 418-00 to diagnose the lost communication with the
With Body Control Generic Electronic Module (GEM).
Module (GEM)
U0155 Lost Communication REFER to Section 418-00 to diagnose the lost communication with the
With Instrument Panel Instrument Cluster (IC).
Cluster (IC) Control
Module
U2050 No Application Present INSTALL a new LTM . REFER to Liftgate/Trunk Module (LTM) in this
section. REPEAT the self-test.
U2051 One or More INSTALL a new LTM . REFER to Liftgate/Trunk Module (LTM) in this
Calibration Files section. REPEAT the self-test.
Missing / Corrupt
U2471 Unexpected PRNDL VERIFY the transmission gear selector (PRNDL) is in PARK. CLEAR the
State DTCs. REPEAT the self-test. If DTC U2471 is retrieved again,
RETRIEVE and FOLLOW non-network DTCs from the Transmission
Control Module (TCM) (if equipped) or PCM and Instrument Cluster (IC)
module. REFER to Section 413-01 and Section 307-01 . If no DTCs are
present, INSTALL a new LTM . REFER to Liftgate/Trunk Module (LTM)
in this section.
U2472 Unexpected Ignition VERIFY the ignition key is in the ON position. CLEAR the DTCs.
State REPEAT the self-test. If DTC U2472 is retrieved again, RETRIEVE and
FOLLOW non-network DTCs from the GEM . REFER to Section 211-05 .
If no DTCs are present, INSTALL a new LTM . REFER to Liftgate/Trunk
Module (LTM) in this section.
U2473 Unexpected Vehicle CLEAR the DTCs. REPEAT the self-test. If DTC U2473 is retrieved
Speed (VSS) again, RETRIEVE and FOLLOW non-network DTCs from the IC .
REFER to Section 413-01 to diagnose the Vehicle Speed Sensor (VSS). If
no related DTCs or symptoms are present, INSTALL a new LTM .
REFER to Liftgate/Trunk Module (LTM) in this section.
Actuator Motor 113

All REFER to the Master DTC Chart in Section 419-10 .

other
DTCs
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test A: The Power Liftgate is Inoperative Does Not Open or Close
Refer to Wiring Diagrams Cell 109 , Power Liftgate for schematic and connector information.
Normal Operation
The Liftgate/Trunk Module (LTM) receives battery voltage at all times through circuits SBP14 (BN/RD) and
SBB36 (GN/RD). Ground is provided to the LTM through circuit GD149 (BK/GY).
During power opening and/or power closing operation, the LTM receives inputs from the following system
components:
Power liftgate control switch (instrument panel), power liftgate close switch (quarter trim panel)
through circuit CPR63 (GY/YE) or Remote Keyless Entry (RKE).
Pinch strip through circuits CPR51 (YE/OG) (RH) and CPR52 (YE/VT) (LH). The pinch strip
switches are grounded through the LTM through circuit RPR52 (VT/GY).
Position sensor through circuits VPR53 (BU/WH) and VPR54 (BU/BN). The position sensor receives
5 volts from the LTM through circuit CPR55 (GN/BU) and ground from the LTM through circuit
RPR55 (WH/BU).
Detent switch through circuit CPR66 (GY/YE).
Forkbolt primary switch through circuit CPR64 (VT/OG).
Forkbolt secondary switch through circuit CPR65 (BU/GN).
Sector gear close switch through circuit CPR67 (VT).
Sector gear open switch through circuit CPR68 (YE).
During power opening and/or power closing operation, the LTM provides output to the following system
components:
Power liftgate clutch through circuit CPR69 (BN/BU). Ground is provided to the clutch through
circuit GD149 (BK/GY).
Power liftgate motor through circuits CPR57 (GN/WH) and CPR58 (GN/OG).
Power liftgate cinch motor through circuits CPR61 (BN) and CPR62 (WH/BU).
Power liftgate chime through circuits CPR56 (VT/BN) and RPR56 (GY/VT).
For detailed description of normal operation, refer to Principles of Operation in this section.
Normal Operation 114

DTC Description Fault Trigger Conditions

This DTC sets when the LTM detects a short to ground in the actuator clutch
B106E Solid power circuit. The power liftgate will be disabled until this DTC is cleared
State Driver (unless LTM DTC B106F is also present).
Disabled Due to
Short Circuit
This DTC sets when the LTM detects a short to ground in the actuator clutch
B106F power circuit repeatedly. This DTC cannot be cleared. REFER to the
Module Disabled Liftgate/Trunk Module (LTM) DTC Chart.
Due to External
Fault
This DTC sets when the LTM detects a short to ground in the latch motor
B117A Latch circuit(s).
Motor Circuit
Short to Ground
This DTC sets when the LTM detects an open in the latch motor circuit(s).
B117B Latch
Motor Circuit
Open
This DTC sets when the LTM detects a short to battery in the latch motor
B1179 Latch circuit(s).
Motor Circuit
Short to Battery
This DTC sets when the LTM detects a short to ground on the position sensor 5
B2418 volt power circuit.
Sensor Power
Short to Ground
This DTC sets when the LTM detects the position sensor feedback signals are not
B2419 correct.
Sensor 1 Invalid
This DTC sets when the LTM detects the position sensor feedback signals are not
B2420 correct.
Sensor 2 Invalid
This DTC sets when the LTM does not detect battery voltage on the high current
B2552 Vbatt. power feed circuit.
2 Circuit Open
This DTC sets when the LTM detects a short to battery in the power liftgate
B2819 Gate motor circuit(s).
Motor Circuit
Short to Battery
This DTC sets when the LTM detects the liftgate is not in the fully latched
B2908 Latch (primary) position at the beginning of Self-Test. This DTC may also be set if the
Switch Invalid LTM does not detect a change in the latch status during latch releasing/cinching.
This DTC sets when the time to complete a LTM Self-Test cycle (power open
B2935 Drive and power close to fully latched position) exceeds 20 seconds.
Unit Failure
This DTC sets when the LTM detects an open in the power liftgate motor
B2936 Gate circuit(s).
Motor Open
This DTC sets when the LTM detects a short to ground in the power liftgate
motor circuit(s).

B2937 Gate
Motor Short to
Ground
This DTC sets when the LTM detects an open or short to ground in the actuator
B2939 Gate clutch power circuit.
Clutch Short to
Ground or Open
This pinpoint test is intended to diagnose the following:

Fuse(s)
Wiring, terminals or connectors
Power liftgate latch
Motor/clutch assembly
LTM
Power liftgate rod
PINPOINT TEST A: THE POWER LIFTGATE IS INOPERATIVE DOES NOT OPEN OR CLOSE
NOTICE: Use the correct probe adapter(s) from the Flex Probe Kit when making measurements.
Failure to use the correct probe adapter(s) may damage the connector.
Test Step Result / Action to Take

A1 RETRIEVE THE DTCs FROM THE LTM
Yes
Use the recorded LTM DTCs from the continuous and LTM For DTC B106F, REFER to
self-tests. the Liftgate/Trunk Module
Are any LTM DTCs recorded? (LTM) DTC Chart.
For DTC B2908, GO to A5 .
For DTCs B2418, B2419 or

B2420, GO to A20 .
For DTC B2936, B2819,

B2937 or B2939, GO to A14 .
For DTC B106E, GO to A16 .
For DTC B1179, B117A or

B117B, GO to A28 .
No
GO to A2 .
A2 CHECK THE OPERATION OF THE POWER LIFTGATE
SWITCHES
116
Vehicle in PARK. Yes

NOTE: Make sure the power liftgate feature is enabled (ON) in GO to Pinpoint Test B .
the vehicle message center.
Close the liftgate to the full closed position (manually if No
necessary). GO to A3 .
Activate the power liftgate from the power liftgate control
switch (instrument panel).
Activate the power liftgate from the remote transmitter.
Activate the power liftgate from the liftgate exterior handle.
Does the liftgate power open from any switch?
A3 CHECK CIRCUIT SBP14 (BN/RD) FOR VOLTAGE
Yes
Disconnect: LTM C4174A. GO to A4 .
Measure the voltage between LTM C4174A-9, circuit SBP14
(BN/RD), harness side and ground. No
VERIFY Smart Junction Box
(SJB) fuse 14 (10A) is OK. If
OK, REPAIR the circuit.
CLEAR the DTCs. REPEAT
the LTM self-test. If not OK,
REFER to the Wiring
Diagrams manual to identify
the possible causes of the
circuit short. CLEAR the
DTCs. REPEAT the LTM
Is the voltage greater than 10 volts?
self-test.
A4 CHECK CIRCUIT GD149 (BK/GY) FOR AN OPEN
Yes
Ignition OFF. RECONNECT power liftgate
Measure the resistance between LTM C4174A-1, circuit GD149 system electrical connectors
(BK/GY), harness side and ground. and GO to A5 .
No
REPAIR the circuit. CLEAR
the DTCs. REPEAT the LTM
self-test.
Is the resistance less than 5 ohms?

A5 CHECK THE DETENT AND FORKBOLT SWITCH PIDs
Yes
Enter the following diagnostic mode on the scan tool: GO to A10 .
DataLogger LTM .
Operate the liftgate manually while monitoring the following No
LTM PIDs: GO to A6 .
Detent Switch Status (DETENTSW)
Forkbolt Switch Status (FORKBLT_S)
Forkbolt Secondary Switch (FKSWSEC)
NOTE: The liftgate is in the primary position when the liftgate
is in the full closed position. The liftgate is in the unlatch
117
position when the liftgate is open and completely out of the

striker. The liftgate can be placed in the unlatched position by
lifting up on the liftgate handle.
Begin with the liftgate in the open position, then slowly close
the liftgate into each of the latch positions specified by the table
below.
Liftgate Latch
Position DETENTSW FKSWSEC FORKBLT_S
Fully Unlatched Inactive a Active Active
Primary Active Inactive Inactive
a If detent switch is active in the fully unlatched position,
manually attempt to rotate the forkbolt towards the latched

position.
Do the switch states agree with the table?
A6 CHECK THE OPERATION OF THE DETENT AND
FORKBOLT SWITCHES
Yes
Ignition OFF. GO to A32 .
Disconnect: LTM C4174B.
Measure the resistance between LTM C4174B, harness side and No
ground at each of the connector pins and each latch position GO to A7 .
specified by the table below.
Liftgate Latch
Position C4174B Circuit Resistance
Fully Unlatched Pin 3, circuit CPR66 Greater than 10,000
(GY/YE) ohms a
Fully Unlatched Pin 5, circuit CPR64 Less than 5 ohms
(VT/OG)
(BU/GN)
Primary Pin 3, circuit CPR66 Less than 5 ohms
(GY/YE)
Primary Pin 5, circuit CPR64 Greater than 10,000
(VT/OG) ohms
(BU/GN) ohms
a If resistance measured is less than 5 ohms, manually rotate the
forkbolt to the latched position and retest.
118
Do the resistance values agree with the table?

A7 CHECK THE DETENT AND FORKBOLT SWITCH
GROUND CIRCUIT
Yes
Disconnect: Liftgate Latch/Unlatch Assembly C4339. GO to A8 .
Measure the resistance between power liftgate latch/unlatch
assembly C4339-8, circuit GD149 (BK/GY), harness side and No
ground. REPAIR the circuit. CLEAR
self-test.

CIRCUITS FOR AN OPEN
Yes
Measure the resistance between power liftgate latch/unlatch GO to A9 .
assembly C4339, harness side and LTM C4174A, harness side
using the following chart: No
self-test.
Power Liftgate Latch/Unlatch

Assembly Circuit LTM
C4339-1 CPR64 C4174B-5
(VT/OG)
C4339-3 CPR65 C4174B-4
(BU/GN)
C4339-2 CPR66 C4174B-3
(GY/YE)
119
Is the resistance less than 5 ohms on all circuits?

CIRCUITS FOR A SHORT TO GROUND
Yes
Measure the resistance between LTM C4174B-5, circuit CPR64 CHECK the power liftgate
(VT/OG), harness side and ground; between LTM C4174B-4, latch connector for bent or
circuit CPR65 (BU/GN), harness side and ground; then between corroded connections on the
LTM C4174B-3, circuit CPR66 (GY/YE), harness side and component side and harness
ground. side. REPAIR as necessary.
INSTALL a new power liftgate

latch. REFER to Section
501-14 . CLEAR the DTCs.
REPEAT the LTM self-test.
No
self-test.
Are the resistances greater than 10,000 ohms on all circuits?
A10 CHECK POWER LIFTGATE ROD OPERATION
Yes
Check for correct function of power liftgate rod and cable. GO to A11 .
Correctly attached to motor and liftgate.
Cable turns with actuator. No
Is the power liftgate rod operating correctly? REPAIR as necessary. If
installing a new power liftgate
rod, REFER to Power Liftgate
Rod in this section. CLEAR
self-test.
A11 CHECK FOR VOLTAGE AT THE POWER LIFTGATE
MOTOR AND CLUTCH
Yes
Ignition ON. If no DTCs were present, GO
Liftgate in the fully closed position. to A19 . If DTCs were present,
With the motor/clutch connected and while activating the power INSTALL a new power liftgate
liftgate control switch, measure the voltage between power motor. REFER to Power
liftgate motor/clutch C4332-1, circuit CPR57 (GN/WH), Liftgate Motor in this section.
backprobe and ground; then between power liftgate CLEAR the DTCs. REPEAT
motor/clutch C4332-2, circuit CPR69 (BN/BU), backprobe and the LTM self-test.
power liftgate motor/clutch C4332-7, circuit GD149 (BK/GY),
backprobe. No
GO to A12 .
120
Are both of the voltages greater than 10 volts while

activating the power liftgate switch?
A12 CHECK THE MOTOR AND CLUTCH VOLTAGE
OUTPUTS AT THE LTM
Yes
With the LTM connected, measure the voltage between LTM GO to A14 .
C4174A-6, circuit CPR58 (GN/OG), backprobe and ground;
then between LTM C4174A-8, circuit CPR69 (BN/BU), No
backprobe and ground. GO to A13 .
Are the voltages greater than 10 volts while activating the

power liftgate switch?
A13 CHECK FOR VOLTAGE AT THE LTM
Yes
Ignition OFF. If you are here because of DTC
Disconnect: LTM C4174A. B2552, GO to A32 .
Measure the voltage between LTM C4174A-4, circuit SBB27 Otherwise, GO to A19 .
(BU/RD), harness side and ground.
No
VERIFY Battery Junction Box
(BJB) fuse 36 (30A) is OK. If
OK, REPAIR the circuit.
the LTM self-test. If not OK,
REFER to the Wiring
Diagrams manual to identify
the possible causes of the
circuit short. CLEAR the
self-test.
A14 CHECK CIRCUIT CLUTCH GROUND CIRCUIT GD149
(BK/GY) FOR AN OPEN
Yes
Disconnect: LTM C4174A.
Disconnect: Power Liftgate Motor C4332. No
Measure the resistance between power liftgate motor C4332-7, REPAIR the circuit. CLEAR
circuit GD149 (BK/GY), harness side and ground. the DTCs. REPEAT the LTM
self-test.
121
Is the resistances less than 5 ohms?

A15 CHECK THE MOTOR/CLUTCH CIRCUITS FOR A
SHORT TO VOLTAGE
Yes
Ignition ON. REPAIR the circuit. CLEAR
Measure the voltage between LTM C4174A-5, circuit CPR57 the DTCs. REPEAT the LTM
(GN/WH), harness side and ground; between LTM C4174A-6, self-test.
circuit CPR58 (GN/OG), harness side and ground; then between
LTM C4174A-8, circuit CPR69 (BN/BU), harness side and No
ground. GO to A16 .
Is any voltage present?

A16 CHECK THE MOTOR/CLUTCH CIRCUITS FOR AN
OPEN
Yes
Measure the resistance between LTM C4174A, harness side and GO to A17 .
the power liftgate motor/clutch C4332, harness side, using the
following chart: No
self-test.
LTM Circuit Power Liftgate Motor/Clutch

C4174A-5 CPR57 (GN/WH) C4332-1
C4174A-6 CPR58 (GN/OG) C4332-5
C4174A-8 CPR69 (BN/BU) C4332-2
Are the resistances less than 5 ohms?
122
A17 CHECK THE MOTOR/CLUTCH CIRCUITS FOR A

SHORT TO GROUND
Yes
Disconnect: Power Liftgate Motor C4332. No
Measure the resistance between LTM C4174A-5, circuit CPR57 REPAIR the circuit. If DTC
(GN/WH), harness side and ground; between LTM C4174A-6, B106E was present, CLEAR
circuit CPR58 (GN/OG), harness side and ground; then between the DTCs. REPEAT the LTM
LTM C4174A-8, circuit CPR69 (BN/BU), harness side and self-test.
ground.
Are the resistances greater than 10,000 ohms?

A18 CHECK THE POWER LIFTGATE MOTOR OPERATION
Yes
Connect: Power Liftgate Motor C4223. GO to A32 .
Manually unlatch the liftgate.
Liftgate in the fully closed and unlatched position. No
NOTICE: Do not apply power and ground to the motor INSTALL a new power liftgate
actuator circuits for more than a few seconds or damage to motor. REFER to Power
the motor may occur. Liftgate Motor in this section.
Momentarily connect a fused jumper wire between LTM CLEAR the DTCs. REPEAT
C4174A-5, circuit CPR57 (GN/WH), harness side and the LTM the LTM self-test.
C4174A-4, circuit SBB07 (WH/RD), harness side; and connect
a fused jumper wire between the LTM C4174A-6, circuit
CPR58 (GN/OG), harness side and the LTM C4174A-1, circuit
GD149 (BK/GY), harness side.
Does the power liftgate motor operate?

A19 CHECK THE POSITION SENSOR PIDs
Yes
Connect: All LTM Connectors.
Connect: Power Liftgate Motor C4332. No
Ignition ON. GO to A20 .
Open the liftgate to the full open position.
123
Enter the following diagnostic mode on the scan tool:

DataLogger LTM .
Monitor the LTM PIDs OPT_SEN_1 and OPT_SEN_2 while
slowly closing the liftgate.
Do both of the PID values alternate from ACTIVE to
INACTIVE while the liftgate is moving?
A20 CHECK THE POSITION SENSOR POWER CIRCUIT
Yes
Disconnect: Power Liftgate Motor C4332. GO to A22 .
Ignition ON.
Measure the voltage between power liftgate motor C4332-4, No
circuit CPR55 (GN/BU), harness side and ground. GO to A21 .
Is the voltage approximately 5 to 7 volts?

A21 CHECK THE POSITION SENSOR POWER CIRCUIT FOR
AN OPEN OR SHORT TO GROUND
Yes
Measure the resistance between LTM C4174B-6, circuit CPR55 No
(GN/BU), harness side and power liftgate motor C4332-4, REPAIR the circuit. CLEAR
circuit CPR55 (GN/BU), harness side; and between LTM the DTCs. REPEAT the LTM
C4174B-6, circuit CPR55 (GN/BU), harness side and ground. self-test.
Is the resistance less than 5 ohms between LTM and power

liftgate motor; and greater than 10,000 ohms between LTM
and ground?
A22 CHECK THE POSITION SENSOR RETURN CIRCUIT
Yes
Disconnect: Power Liftgate Motor C4332.
Ignition ON. No
Measure the resistance between power liftgate motor C4332-9, GO to A23 .
circuit RPR55 (WH/BU), harness side and ground.
124

A23 CHECK THE POSITION SENSOR RETURN CIRCUIT
FOR AN OPEN
Yes
Measure the resistance between LTM C4174B-7, circuit RPR55 No
(WH/BU), harness side and power liftgate motor C4332-9, REPAIR the circuit. CLEAR
circuit RPR55 (WH/BU), harness side. the DTCs. REPEAT the LTM
self-test.

A24 CHECK THE POSITION SENSOR CIRCUITS FOR AN
OPEN
Yes
Ignition ON. INSTALL a new power liftgate
Measure the voltage between power liftgate motor C4332-8, motor. REFER to Power
circuit VPR53 (BU/WH), harness side and ground; and between Liftgate Motor in this section.
power liftgate motor C4332-3, circuit VPR54 (BU/BN), harness CLEAR the DTCs. REPEAT
side and ground. the LTM self-test.
No
GO to A25 .
Is the voltage approximately 5 volts for both measurements?

A25 CHECK THE POSITION SENSOR CIRCUITS FOR AN
OPEN
125
Ignition OFF. Yes

Disconnect: LTM C4174B. GO to A26 .
Measure the resistance between power liftgate motor C4332,
harness side and LTM C4174B, harness side using the following No
chart: REPAIR the circuit. CLEAR
self-test.
Power Liftgate Motor Circuit LTM

C4332-8 VPR53 (BU/WH) C4174B-21
C4332-3 VPR54 (BU/BN) C4174B-20

A26 CHECK THE POSITION SENSOR CIRCUITS FOR A
SHORT TO GROUND
Yes
Measure the resistance between power liftgate motor C4332-3, GO to A27 .
circuit VPR54 (BU/BN), harness side and ground; and between
power liftgate motor C4332-8, circuit VPR53 (BU/WH), No
harness side and ground. REPAIR the circuit. CLEAR
self-test.

A27 CHECK THE POSITION SENSOR CIRCUITS FOR A
SHORT TO VOLTAGE
Yes
Measure the voltage between power liftgate motor C4332-3, the DTCs. REPEAT the LTM
circuit VPR54 (BU/BN), harness side and ground; and between self-test.
power liftgate motor C4332-8, circuit VPR53 (BU/WH),
harness side and ground. No
GO to A32 .
126

A28 CHECK THE UNLATCH/CINCHING MOTOR CIRCUITS
Yes
Close the power liftgate. No
NOTICE: Do not apply power and ground to the unlatch GO to A29 .
actuator circuits for more than a few seconds or damage to
the motor may occur.
Connect a fused jumper wire between LTM C4174A-3, circuit
CPR62 (WH/BU), harness side and the positive side of the
battery; and connect a jumper between LTM C4174A-2, circuit
CPR61 (BN), harness side and ground.
Does the unlatch/cinching motor activate when power and

ground are applied?
FOR AN OPEN
Yes
Disconnect: Liftgate Latch/Unlatch Assembly C4339. GO to A30 .
Measure the resistance between power liftgate latch C4339,
harness side and LTM C4174A, harness side, using the No
following chart: REPAIR the circuit. CLEAR
self-test.
Liftgate Latch/Unlatch
C4339-5 CPR61 (BN) C4174A-2
C4339-7 CPR62 C4174A-3
(WH/BU)
127

FOR A SHORT TO GROUND
Yes
Measure the resistance between power liftgate latch C4339-5, GO to A31 .
circuit CPR61 (BN), harness side and ground; then between
power liftgate latch C4339-7, circuit CPR62 (WH/BU), harness No
side and ground. REPAIR the circuit. CLEAR
self-test.

A31 CHECK THE UNLATCH ACTUATOR CIRCUITS FOR A
SHORT TO VOLTAGE
Yes
Measure the voltage between power liftgate latch C4339-5, the DTCs. REPEAT the LTM
circuit CPR61 (BN), harness side and ground; then between self-test.
power liftgate latch C4339-7, circuit CPR62 (WH/BU), harness
side and ground. No
CHECK the power liftgate
latch connectors for bent or
corroded connections on the
component side and harness
side. REPAIR as necessary.

latch. REFER to Section
Is voltage present on either circuit?
A32 CHECK FOR CORRECT LTM OPERATION
Yes
Disconnect all the LTM connectors. INSTALL a new LTM .
Check for: REFER to Liftgate/Trunk
corrosion. Module (LTM) in this section.
pushed-out pins. REPEAT the LTM self-test.
Connect all the LTM connectors and make sure they are seated
correctly. No
Make sure the liftgate is fully CLOSED. The system is operating
128
Operate the system and verify the concern is still present. correctly at this time. Concern
Is the concern still present? may have been caused by a
loose or corroded connector.
the LTM self-test.
Pinpoint Test B: The Power Liftgate is Inoperative From an Individual Switch
Normal Operation
If the power liftgate is operated from the power liftgate control switch (instrument panel), circuit CPR63
(GY/YE) is grounded by the open/close switch, which signals the Liftgate/Trunk Module (LTM) of the
open/close request. If the power liftgate is operated from the rear switch (quarter trim panel), circuit CPR70
(GN) is grounded by the rear switch through circuit GD149 (BK/GY). If the power liftgate is operated from
the liftgate handle, the Smart Junction Box (SJB) sends a voltage signal to the LTM through circuit CPL10
(GN/WH).

This DTC sets when the SJB detects a short to ground on the
B2666 Liftgate Release Switch liftgate release handle switch input circuit.
Circuit Failure
This DTC sets when the SJB detects a short to ground on the
B273A Liftgate Release Output liftgate release handle switch output circuit.
Circuit Shorted to Ground
This DTC sets when the SJB detects a open or short to battery
B273B Liftgate Release Output on the liftgate release handle switch output circuit.
Circuit Open or Shorted to Battery
Voltage
This DTC sets when the LTM detects that the power liftgate
B1105 Rear Open/Close Switch rear control switch (quarter trim panel) is stuck active (or a
Active During Self Test short to ground is present in the circuit).
This DTC sets when the LTM detects that the power liftgate
B2703 Open/Close Switch control switch (instrument panel) is stuck active (or a short to
Stuck Active ground is present in the circuit).

Power liftgate control switch (instrument panel)
Power liftgate rear control switch (quarter trim panel)
LTM
SJB

PINPOINT TEST B: THE POWER LIFTGATE IS INOPERATIVE FROM AN INDIVIDUAL SWITCH

B1 RETRIEVE THE DTCs FROM THE LTM AND THE
SJB
Yes
Use the recorded LTM DTCs and SJB DTCs from the For SJB DTC B2666, REFER to
continuous and self-tests. Section 501-14 to diagnose the liftgate
Are any LTM DTCs present? handle release switch.
For SJB module DTC B273A or

B273B, GO to B4 .
For LTM DTC B1105, GO to B8 .
For LTM DTC B2703, GO to B12 .
No
GO to B2 .
B2 CHECK THE OPERATION OF THE POWER
LIFTGATE SWITCHES
Yes
NOTE: Make sure the power liftgate feature is ON If the power liftgate control switch is
(enabled) in the message center. inoperative, GO to B12 .
Close the liftgate to the full closed position (manually if
necessary). If the exterior handle is inoperative, GO
Electronically unlock the vehicle. to B3 .
Activate the power liftgate from the power liftgate
control switch (instrument panel). If the remote transmitter is inoperative,
Activate the power liftgate from the remote transmitter. GO to Symptom Chart .
Activate the power liftgate from the liftgate exterior
handle. If the power liftgate rear control switch
With the liftgate in the open position, activate the power is inoperative, GO to B8 .
liftgate from the power liftgate rear control switch
(quarter trim panel). No
Does the power liftgate open/close from at least one GO to Pinpoint Test A to diagnose an
switch? inoperative power liftgate.
B3 CHECK THE LIFTGATE HANDLE PID
Yes
Ignition ON. GO to B4 .
DataLogger SJB . No
Monitor the SJB PID GATE_SW while activating the REFER to Section 501-14 to diagnose
liftgate release handle. the liftgate handle release switch.
Does the switch change states from INACTIVE to
ACTIVE when the liftgate release handle is
activated?
B4 CHECK THE SJB RELEASE CIRCUIT OUTPUT

130
Disconnect: LTM C4174B. Yes

Measure the voltage between LTM C4174B-12, circuit GO to B16 .
CPL10 (GN/WH), harness side and ground while
commanding the liftgate open from the power liftgate No
control switch (instrument panel). GO to B5 .
Is the voltage greater than 10 volts when the power

liftgate control switch is activated, and
approximately 5 volts when the power liftgate
control switch is inactive?
B5 CHECK CIRCUIT CPL10 (GN/WH) FOR A SHORT
TO VOLTAGE
Yes
Ignition OFF. REPAIR the circuit. CLEAR the DTCs.
Disconnect: SJB Module C2280E. REPEAT the SJB self-test.
Ignition ON.
Measure the voltage between LTM C4174B-12, circuit No
CPL10 (GN/WH), harness side and ground. GO to B6 .

B6 CHECK CIRCUIT CPL10 (GN/WH) FOR AN OPEN
OR SHORT TO GROUND
Yes
Measure the resistance between LTM C4174B-12, GO to B7 .
circuit CPL10 (GN/WH), harness side and SJB
C2280E-15, circuit CPL10 (GN/WH), harness side; and No
between LTM C4174B-12, circuit CPL10 (GN/WH), REPAIR the circuit. CLEAR the DTCs.
harness side and ground. REPEAT the SJB self-test.

131
Is the resistance less than 5 ohms between LTM and

the SJB ; and greater than 10,000 ohms between
LTM and ground?
B7 CHECK FOR CORRECT SJB MODULE
OPERATION
Yes
Disconnect all the SJB and LTM connectors. INSTALL a new SJB module.
Check for: REPEAT the SJB module self-test.
corrosion.
pushed-out pins. No
Connect all the SJB and LTM connectors and make The system is operating correctly at this
sure they are seated correctly. time. Concern may have been caused
Make sure the liftgate is fully CLOSED. by a loose or corroded connector.
Operate the system and verify the concern is still CLEAR the DTCs. REPEAT the SJB
present. module self-test.
Is the concern still present?
B8 CHECK THE REAR/OPEN SWITCH (REAR_OC)
PID
Yes
Enter the following diagnostic mode on the scan tool: GO to B16 .
DataLogger LTM .
Monitor the LTM PID REAR_OC while operating the No
power liftgate rear control switch. GO to B9 .
Does the PID state change or agree with the rear
control switch status?
B9 CHECK POWER LIFTGATE REAR SWITCH
CIRCUIT OPERATION
Yes
Disconnect: LTM C4174B. GO to B16 .
Measure the resistance between LTM C4174B-24,
circuit CPR70 (GN), harness side and ground while No
depressing and releasing the power liftgate rear switch. GO to B10 .
Is the resistance less than 10 ohms with the power

liftgate rear switch depressed, and greater than
10,000 ohms when the power liftgate rear switch is
released?
B10 CHECK CIRCUIT GD149 (BK/GY) FOR AN OPEN

132
Ignition OFF. Yes

Disconnect: Power Liftgate Rear Open/Close Switch GO to B11 .
C4333.
Measure the resistance between power liftgate rear No
switch C4333-5, circuit GD149 (BK/GY), harness side REPAIR the circuit. CLEAR the DTCs.
and ground. REPEAT the LTM self-test.

B11 CHECK CIRCUIT CPR70 (GN) FOR AN OPEN OR
SHORT TO GROUND
Yes
Measure the resistance between LTM C4174B-24, INSTALL a new power liftgate rear
circuit CPR70 (GN), harness side and power liftgate switch. CLEAR the DTCs. REPEAT
rear switch C4333-1, circuit CPR70 (GN), harness side; the LTM self-test.
and between LTM C4174B-24, circuit CPR70 (GN),
REPAIR the circuit. CLEAR the DTCs.

power liftgate rear switch; and greater than 10,000
ohms between LTM and ground?
B12 CHECK THE LIFTGATE RELEASE SWITCH
STATUS (PLGM_SW) PID
Yes
Enter the following diagnostic mode on the scan tool: GO to B16 .
DataLogger LTM .
Monitor the LTM PID PLGM_SW while operating the No
power liftgate control switch (instrument panel). GO to B13 .
Does the PID state change/agree with the switch
status?
B13 CHECK POWER LIFTGATE CONTROL SWITCH
CIRCUIT OPERATION

133
Disconnect: LTM C4174B. Yes

Measure the resistance between LTM C4174B-16, GO to B16 .
circuit CPR63 (GY/YE), harness side and ground while
depressing and releasing the power liftgate control No
switch (instrument panel). GO to B14 .
Is the resistance less than 13 ohms with the power

liftgate control switch depressed, and greater than
10,000 ohms when the power liftgate control switch
is released?
B14 CHECK CIRCUIT GD138 (BK/WH) FOR AN OPEN
Yes
Ignition OFF. GO to B15 .
Disconnect: Liftgate/Traction Control/Hazard Switch
C2361. No
Measure the resistance between power liftgate control REPAIR the circuit. CLEAR the DTCs.
switch C2361-4, circuit GD138 (BK/WH), harness side REPEAT the LTM self-test.
and ground.

B15 CHECK CIRCUIT GD138 (BK/WH) FOR AN OPEN
OR SHORT TO GROUND
Yes
Measure the resistance between LTM C4174B-16, INSTALL a new liftgate/traction
circuit CPR63 (GY/YE), harness side and power liftgate control/hazard switch. CLEAR the
control switch C2361-7, circuit CPR63 (GY/YE), DTCs. REPEAT the LTM self-test.
harness side; and between LTM C2361-7, circuit
CPR63 (GY/YE), harness side and ground. No
REPEAT the LTM self-test. TEST the
system for normal operation.

134

power liftgate control switch; and greater than
10,000 ohms between LTM and ground?
B16 CHECK FOR CORRECT LTM OPERATION
Yes
Disconnect all the LTM connectors. INSTALL a new LTM . REFER to
Check for: Liftgate/Trunk Module (LTM) in this
corrosion. section. REPEAT the LTM self-test.
pushed-out pins.
Connect all the LTM connectors and make sure they are No
seated correctly. The system is operating correctly at this
Make sure the liftgate is fully CLOSED. time. Concern may have been caused
Operate the system and verify the concern is still by a loose or corroded connector.
present. CLEAR the DTCs. REPEAT the LTM
Is the concern still present? self-test.
Pinpoint Test C: The Power Liftgate Does Not Operate Correctly Stops in Secondary Latch
Position (Does Not Pull into Primary Latch Position)
Normal Operation
When the power liftgate moves in the close direction, the Liftgate/Trunk Module (LTM) monitors the detent
switch, secondary forkbolt switch and the primary forkbolt switch. When the combination of signals is
received that indicates the liftgate has reached the secondary latch position, the LTM supplies 12 volts to the
unlatch/cinching motor on circuit CPR61 (BN) and ground on circuit CPR62 (WH/BU). The unlatch/cinching
motor rotates the latch mechanism which pulls the liftgate into primary latch position.
DTC B2019 (Liftgate Exceeded Time Allowed to Cinch Door) If the cinching sequence has been
active for more than 5 seconds the latch cinching sequence will time out and the LTM will set this
DTC.
DTC B2908 (Latch Switch Invalid) This DTC sets when the LTM detects the liftgate is not in the
fully latched (primary) position at the beginning of Self-Test. This DTC may also be set if the LTM
does not detect a change in the latch status during latch releasing/cinching.

Liftgate alignment
Latch striker alignment
LTM

PINPOINT TEST C: THE POWER LIFTGATE DOES NOT OPERATE CORRECTLY STOPS IN SECONDARY
LATCH POSITION (DOES NOT PULL INTO PRIMARY LATCH POSITION)

C1 RETRIEVE THE DTCs FROM THE LTM
Yes
Use the recorded LTM DTCs from the continuous and self-tests. CHECK the liftgate
Is LTM DTC B2019 present? alignment. REFER to
Liftgate Alignment in this
section. If OK, GO to C2 .
No
GO to C2 .
C2 CHECK THE DETENT AND FORKBOLT SWITCH PIDs
Yes
Enter the following diagnostic mode on the scan tool: DataLogger GO to C7 .
LTM .
Operate the liftgate manually while monitoring the following LTM No
PIDs: GO to C3 .
NOTE: The liftgate is in the primary position when the liftgate is
in the full closed position. The liftgate is in the unlatch position
when the liftgate is open and completely out of the striker. The
liftgate can be placed in the unlatched position by lifting up on the
liftgate handle.
Begin with the liftgate in the open position, then slowly close the
liftgate into each of the latch positions specified by the table below.
Liftgate Latch
Position DETENTSW FORKBLT_S FKSWSEC
a If detent switch is active in the fully unlatched position, manually
attempt to rotate the forkbolt towards the latched position.

C3 CHECK THE OPERATION OF THE DETENT AND
FORKBOLT SWITCHES
Yes
Ignition OFF. GO to C7 .
ground at each of the connector pins and each latch position GO to C4 .
PINPOINT TEST C: THE POWER LIFTGATE DOES NOT OPERATE CORRECTLY STOPS136
IN SECON
Liftgate Latch
(GY/YE) ohms a
(VT/OG)
(BU/GN)
(GY/YE)
(VT/OG) ohms
(BU/GN) ohms

C4 CHECK THE DETENT AND FORKBOLT SWITCH GROUND
CIRCUIT
Yes
Disconnect: Power Liftgate Latch/Unlatch Assembly C4339. GO to C5 .
Measure the resistance between power liftgate latch C4339-8,
circuit GD149 (BK/GY), harness side and ground. No
REPAIR the circuit.
CLEAR the DTCs.

C5 CHECK THE DETENT AND FORKBOLT SWITCH CIRCUITS
FOR AN OPEN
IN SECON
Measure the resistance between power liftgate latch/unlatch Yes

assembly C4339, harness side and LTM C4174A, harness side GO to C6 .
using the following chart:
No
REPAIR the circuit.
CLEAR the DTCs.
C4339-1 CPR64 C4174B-5
(VT/OG)
C4339-3 CPR65 C4174B-4
(BU/GN)
C4339-2 CPR66 C4174B-3
(GY/YE)

C6 CHECK THE DETENT AND FORKBOLT SWITCH CIRCUITS
Yes
(VT/OG), harness side and ground; then between LTM C4174B-4, latch connectors for bent or
LTM C4174B-3, circuit CPR66 (GY/YE), harness side and ground. component side and harness
INSTALL a new power

liftgate latch. REFER to
Section 501-14 . CLEAR
the DTCs. REPEAT the
LTM self-test.
No
REPAIR the circuit.
Is the resistance greater than 10,000 ohms on all circuits?
CLEAR the DTCs.
C7 CHECK FOR CORRECT LTM OPERATION
Yes
corrosion. Module (LTM) in this
pushed-out pins. section. REPEAT the LTM
Connect all the LTM connectors and make sure they are seated self-test.
correctly.
IN SECON
Make sure the liftgate is fully CLOSED. No

Operate the system and verify the concern is still present. The system is operating
Is the concern still present? correctly at this time.
Concern may have been
caused by a loose or
corroded connector. CLEAR
LTM self-test.
Pinpoint Test D: The Power Liftgate Does Not Operate Correctly Reverses During the Power Close
Operation
Normal Operation
When the power liftgate moves in the close direction, the Liftgate/Trunk Module (LTM) monitors the pinch
strips and position sensor for obstacle detection. The LTM uses a 5-volt reference signal on circuit CPR52
(YE/VT) and a return signal on circuit RPR52 (VT/GY) for the left pinch strip. The LTM uses a 5-volt
reference signal on circuit CPR51 (YE/OG) and a return signal on circuit RPR52 (VT/GY) for the right pinch
strip. The right and left pinch strip return signal circuits are spliced together.
The position sensor receives 5 volts from the LTM through circuit CPR55 (GN/BU) and ground from the
LTM through circuit RPR55 (WH/BU). The position sensor output signal is supplied to the LTM through
circuit VPR53 (BU/WH) and VPR54 (BU/BN).
DTC B107D (Obstacle Detected While Closing) The LTM will set this DTC if an obstacle is
detected during powered open/close during self-test only.
DTC B2419 (Sensor 1 Invalid) This DTC sets when the LTM detects the position sensor
feedback signals are not correct.
DTC B2420 (Sensor 2 Invalid) This DTC sets when the LTM detects the position sensor
feedback signals are not correct.

Mechanical binding
Power liftgate latch striker alignment
LTM
Wedges
PINPOINT TEST D: THE POWER LIFTGATE DOES NOT OPERATE CORRECTLY REVERSES DURING THE
POWER CLOSE OPERATION

D1 CHECK THE MANUAL OPERATION OF THE LIFTGATE

Turn the power liftgate feature OFF (disable) from the message Yes
center. If the liftgate reverses near
While manually opening and closing the liftgate, check the liftgate the midpoint of travel, GO
for: to D2 .
liftgate/wedge alignment.
strut operation (struts should push open liftgate when If the liftgate reverses near
beyond half open). or at the latch, GO to D11 .
power liftgate rod (should move freely while manually
opening and closing liftgate and should be securely No
mounted to the liftgate and bracket). REPAIR as necessary.
power liftgate latch (should latch completely). ALIGN as necessary.
Does the liftgate open and close correctly? REFER to Liftgate
Alignment in this section.
CLEAR the DTCs.
D2 CHECK THE POSITION SENSOR PID
Yes
Ignition OFF. GO to D11 .
Connect: All LTM Connectors.
Connect: Power Liftgate Motor C4332. No
Ignition ON. GO to D3 .
Open the liftgate to the full open position.
Enter the following diagnostic mode on the scan tool: DataLogger
LTM .
Monitor the LTM PIDs OPT_SEN_1 and OPT_SEN_2 while
slowly closing the liftgate.
Do both of the PID values alternate from ACTIVE to
INACTIVE while the liftgate is moving?
D3 CHECK THE POSITION SENSOR POWER CIRCUIT
Yes
Disconnect: Power Liftgate Motor C4332. GO to D5 .
Ignition ON.
Measure the voltage between power liftgate motor C4332-4, circuit No
CPR55 (GN/BU), harness side and ground. GO to D4 .
Is the voltage approximately 5 to 7 volts?

D4 CHECK THE POSITION SENSOR POWER CIRCUIT FOR AN
OPEN OR SHORT TO GROUND
Yes
Measure the resistance between LTM C4174B-6, circuit CPR55 No
(GN/BU), harness side and power liftgate motor C4332-4, circuit REPAIR the circuit.
CPR55 (GN/BU), harness side; and between LTM C4174B-6, CLEAR the DTCs.
PINPOINT TEST D: THE POWER LIFTGATE DOES NOT OPERATE CORRECTLY REVERSES
140 DURI
circuit CPR55 (GN/BU), harness side and ground. REPEAT the LTM self-test.
Is the resistance less than 5 ohms between LTM and power

liftgate motor; and greater than 10,000 ohms between LTM
and ground?
D5 CHECK THE POSITION SENSOR RETURN CIRCUIT
Yes
Disconnect: Power Liftgate Motor C4332.
Ignition ON. No
Measure the resistance between power liftgate motor C4332-9, GO to D6 .
circuit RPR55 (WH/BU), harness side and ground.

D6 CHECK THE POSITION SENSOR RETURN CIRCUIT FOR
AN OPEN
Yes
Measure the resistance between LTM C4174B-7, circuit RPR55 No
(WH/BU), harness side and power liftgate motor C4332-9, circuit REPAIR the circuit.
RPR55 (WH/BU), harness side. CLEAR the DTCs.

D7 CHECK THE POSITION SENSOR CIRCUITS FOR AN OPEN
141 DURI
Ignition ON. Yes

Measure the voltage between power liftgate motor C4332-8, circuit INSTALL a new power
VPR53 (BU/WH), harness side and ground; and between power liftgate motor. REFER to
liftgate motor C4332-3, circuit VPR54 (BU/BN), harness side and Power Liftgate Motor in this
ground. section. CLEAR the DTCs.
No
GO to D8 .
Is the voltage approximately 5 volts for both measurements?

D8 CHECK THE POSITION SENSOR CIRCUITS FOR AN OPEN
Yes
Measure the resistance between power liftgate motor C4332, No
harness side and LTM C4174B, harness side using the following REPAIR the circuit.
chart: CLEAR the DTCs.
Power Liftgate Motor Circuit LTM

C4332-8 VPR53 (BU/WH) C4174B-21
C4332-3 VPR54 (BU/BN) C4174B-20

D9 CHECK THE POSITION SENSOR CIRCUITS FOR A SHORT
TO GROUND
Yes
Measure the resistance between power liftgate motor C4332-3, GO to D10 .
circuit VPR54 (BU/BN), harness side and ground; and between
power liftgate motor C4332-8, circuit VPR53 (BU/WH), harness No
side and ground. REPAIR the circuit.
CLEAR the DTCs.
142 DURI

D10 CHECK THE POSITION SENSOR CIRCUITS FOR A SHORT
TO VOLTAGE
Yes
Ignition ON. REPAIR the circuit.
Measure the voltage between power liftgate motor C4332-3, circuit CLEAR the DTCs.
VPR54 (BU/BN), harness side and ground; and between power REPEAT the LTM self-test.
liftgate motor C4332-8, circuit VPR53 (BU/WH), harness side and
ground. No
GO to D16 .

D11 CHECK THE DETENT AND FORKBOLT SWITCH PIDs
Yes
Enter the following diagnostic mode on the scan tool: DataLogger GO to D16 .
LTM .
PIDs: GO to D12 .
NOTE: The liftgate is in the primary position when the liftgate is
in the full closed position. The liftgate is in the unlatch position
when the liftgate is open and completely out of the striker. The
liftgate can be placed in the unlatched position by lifting up on the
liftgate handle.
Liftgate Latch
In primary Active Inactive Inactive
a If detent switch is active in the fully unlatched position, manually

143 DURI
D12 CHECK THE OPERATION OF THE DETENT AND

FORKBOLT SWITCHES
Yes
ground at each of the connector pins and each latch position GO to D13 .
Liftgate Latch
(GY/YE) ohms a
(VT/OG)
(BU/GN)
(GY/YE)
(VT/OG) ohms
(BU/GN) ohms

D13 CHECK THE DETENT AND FORKBOLT SWITCH GROUND
CIRCUIT
Yes
Disconnect: Liftgate Latch/Unlatch Assembly C4339. GO to D14 .
ground. REPAIR the circuit.
CLEAR the DTCs.
144 DURI

D14 CHECK THE DETENT AND FORKBOLT SWITCH
Yes
Measure the resistance between power liftgate latch/unlatch GO to D15 .
REPAIR the circuit. TEST
the system for normal
operation.

C4339-1 CPR64 C4174B-5
(VT/OG)
C4339-3 CPR65 C4174B-4
(BU/GN)
C4339-2 CPR66 C4174B-3
(GY/YE)

D15 CHECK THE DETENT AND FORKBOLT SWITCH
Yes
INSTALL a new power

LTM self-test.
No
145 DURI
Are the resistances greater than 10,000 ohms on all circuits? REPAIR the circuit.
CLEAR the DTCs.
D16 CHECK FOR CORRECT LTM OPERATION
Yes
correctly.
corroded connector. CLEAR
LTM self-test.
Pinpoint Test E: The Power Liftgate Chime is Inoperative
Normal Operation
The power liftgate chime is controlled by the Liftgate/Trunk Module (LTM). To activate the chime, the LTM
supplies a high frequency voltage output on circuit CPR56 (VT/BN) and ground on circuit RPR56 (GY/VT).
DTC B236A (Chime Output Circuit Open) This DTC will set when the LTM detects an open in
the chime output circuit.
DTC B2903 (Chime Output Circuit Short to Battery) This DTC will set when the LTM detects a
short to voltage in the chime output circuit.
DTC B2940 (Chime Output Circuit Short to Ground) This DTC will set when the LTM detects a
short to ground in the chime output circuit.

PINPOINT TEST E: THE POWER LIFTGATE CHIME IS INOPERATIVE

E1 CHECK FOR VOLTAGE TO THE POWER LIFTGATE
CHIME

Ignition ON. Yes

Set the parking brake to the ON position. INSTALL a new power
Open the liftgate. liftgate motor. REFER to
NOTE: The LTM applies voltage to the power liftgate chime for Power Liftgate Motor in this
one second after the rear power liftgate switch is pressed, when section. CLEAR the DTCs.
the transmission is not in the PARK position and the liftgate is in REPEAT the LTM self-test.
the OPEN position.
With the power liftgate chime still connected, press the rear power No
liftgate switch and measure the voltage between power liftgate GO to E2 .
chime C4186-1, circuit CPR56 (VT/BN), back probe and power
liftgate chime C4186-2, circuit RPR56 (GY/VT), back probe.
Is any AC voltage present?

E2 CHECK THE POWER LIFTGATE CHIME CIRCUITS FOR
AN OPEN
Yes
Ignition OFF. GO to E3 .
Disconnect: Power Liftgate Chime C4186.
Disconnect: LTM C4174B. No
Measure the resistance between LTM C4174B, harness side and REPAIR the circuit. CLEAR
power liftgate chime C4186, harness side using the following the DTCs. REPEAT the
chart: LTM self-test.
LTM Circuit Power Liftgate Chime

C4174B-9 CPR56 (VT/BN) C4186-1
C4174B-22 RPR56 (GY/VT) C4186-2

E3 CHECK THE POWER LIFTGATE CHIME CIRCUITS FOR A
SHORT TO GROUND
PINPOINT TEST E: THE POWER LIFTGATE CHIME IS INOPERATIVE 147

Measure the resistance between power liftgate chime C4186-1, Yes

circuit CPR56 (VT/BN), harness side and ground; then between GO to E4 .
power liftgate chime C4186-2, circuit RPR56 (GY/VT), harness
side and ground. No
LTM self-test.

E4 CHECK THE POWER LIFTGATE CHIME CIRCUITS FOR A
SHORT TO VOLTAGE
Yes
Measure the voltage between power liftgate chime C4186-1, REPAIR the circuit. CLEAR
circuit CPR56 (VT/BN), harness side and ground; then between the DTCs. REPEAT the
power liftgate chime C4186-2, circuit RPR56 (GY/VT), harness LTM self-test.
side and ground.
No
GO to E5 .

E5 CHECK FOR CORRECT LTM OPERATION
Yes
correctly.
caused by a loose or corroded
connector. CLEAR the
self-test.
Pinpoint Test F: The Power Liftgate Does Not Operate Correctly Pinch Strip Does Not
Stop/Reverse the Liftgate
PINPOINT TEST E: THE POWER LIFTGATE CHIME IS INOPERATIVE 148

Normal Operation

Pinch strip(s)
LTM
PINPOINT TEST F: THE POWER LIFTGATE DOES NOT OPERATE CORRECTLY PINCH STRIP DOES NOT
STOP/REVERSE THE LIFTGATE

F1 RETRIEVE THE DTCs FROM THE
LTM
Yes
Use the recorded LTM DTCs from the GO to Pinpoint Test G .
continuous and LTM self-tests.
Is DTC B2699, B2700, B2701 or No
B2702 present? GO to F2 .
F2 CHECK THE LIFTGATE
LEFT/RIGHT PINCH STRIP STATUS
(LFT_PINCH / RT_PINCH) OPERATION
Yes
Enter the following diagnostic mode GO to F3 .
on the scan tool: DataLogger
LTM . No
Monitor the LTM PIDs LFT_PINCH INSTALL a new left or right pinch strip switch. REFER
and RT_PINCH while activating the to Pinch Strip Switch in this section. TEST the system
left and right pinch strips. for normal operation.
Does the PID state change/agree
with the pinch strip status?
F3 CHECK FOR CORRECT LTM
OPERATION
Yes
Disconnect all the LTM connectors. INSTALL a new LTM . REFER to Liftgate/Trunk
Check for: Module (LTM) in this section. REPEAT the LTM
corrosion. self-test.
pushed-out pins.
Connect all the LTM connectors and No
make sure they are seated correctly. The system is operating correctly at this time. Concern
Make sure the liftgate is fully may have been caused by a loose or corroded connector.
CLOSED. CLEAR the DTCs. REPEAT the LTM self-test.
Operate the system and verify the
concern is still present.

Pinpoint Test G: The Power Liftgate Does Not Power Close (Power Open OK)
Normal Operation

This DTC is set when the LTM detects an open or short to battery
B2699 Left Pinch Strip in the left pinch strip circuit.
Open or Short to Battery
This DTC is set when the LTM detects an open or short to battery
B2700 Right Pinch Strip in the right pinch strip circuit.
This DTC is set when the LTM detects a short to ground in the left
B2701 Left Pinch Strip pinch strip circuit.
Stuck Active
This DTC is set when the LTM detects a short to ground in the right
B2702 Right Pinch Strip pinch strip circuit.
Stuck Active
NOTE: Initialize the power liftgate before proceeding with this pinpoint test. Refer to Power Liftgate
Initialization in this section.

Pinch strip
LTM
PINPOINT TEST G: THE POWER LIFTGATE DOES NOT POWER CLOSE (POWER OPEN OK)

G1 RETRIEVE THE DTCs FROM THE LTM
Yes
GO to G2 .
PINPOINT TEST F: THE POWER LIFTGATE DOES NOT OPERATE CORRECTLY PINCH 150
STRIP DOE
Use the recorded LTM DTCs from the continuous and LTM
self-tests. No
Is DTC B2699, B2700, B2701 or B2702 present? GO to G9 .
G2 CHECK THE LIFTGATE LEFT/RIGHT PINCH STRIP
STATUS (LFT_PINCH / RT_PINCH) OPERATION
Yes
Enter the following diagnostic mode on the scan tool: DataLogger GO to G14 .
LTM .
Monitor the LTM PIDs LFT_PINCH and RT_PINCH while No
activating the left and right pinch strips. GO to G3 .
Does the PID state change/agree with the pinch strip status?
G3 CHECK THE PINCH STRIP SIGNAL CIRCUIT
Yes
Ignition OFF. GO to G7 .
Disconnect: Pinch Strip (Left C4172 or Right C4173).
Ignition ON. No
Measure the voltage between left pinch strip C4172-1, circuit If the voltage measured was
CPR52 (YE/VT), harness side and ground; and between right pinch greater than 5 volts, GO to
strip C4173-1, circuit CPR51 (YE/OG), harness side and ground. G4 . If the voltage
measured was less than 5
volts, GO to G5 .
Is the voltage approximately 5 volts?

G4 CHECK THE PINCH STRIP SIGNAL CIRCUIT FOR SHORT
TO VOLTAGE
Yes
Ignition OFF. REPAIR the circuit(s).
Disconnect: LTM C4174B. CLEAR the DTCs.
Ignition ON. REPEAT the LTM self-test.
Measure the voltage between left pinch strip C4172-1, circuit
CPR52 (YE/VT), harness side and ground; and between right pinch No
strip C4173-1, circuit CPR51 (YE/OG), harness side and ground. GO to G14 .

G5 CHECK THE PINCH STRIP SIGNAL CIRCUIT FOR A SHORT
TO GROUND
PINPOINT TEST G: THE POWER LIFTGATE DOES NOT POWER CLOSE (POWER OPEN OK)151
Ignition OFF. Yes

Disconnect: LTM C4174B. GO to G6 .
Measure the resistance between left pinch strip C4172-1, circuit
CPR52 (YE/VT), harness side and ground; or between right pinch No
strip C4173-1, circuit CPR51 (YE/OG), harness side and ground. REPAIR the circuit.
CLEAR the DTCs.
Is the resistance greater than 10,000 ohms?

G6 CHECK THE PINCH STRIP SIGNAL CIRCUITS FOR AN
OPEN
Yes
Measure the resistance between left pinch strip C4172-1, circuit GO to G14 .
CPR52 (YE/VT), harness side and LTM C4174B-25, circuit CPR52
(YE/VT), harness side. No
REPAIR the circuit.
CLEAR the DTCs.
Then measure the resistance between right pinch strip C4173-1,

circuit CPR51 (YE/OG), harness side and LTM C4174B-1, circuit
CPR51 (YE/OG), harness side.

G7 CHECK THE PINCH STRIP RETURN CIRCUIT
Yes
Ignition ON. INSTALL a new pinch
Measure the resistance between left pinch strip C4172-2, circuit strip. REFER to Pinch Strip
RPR52 (VT/GY), harness side and ground; and between right pinch Switch in this section.
strip C4173-2, circuit RPR52 (VT/GY), harness side and ground. CLEAR the DTCs.
No
GO to G8 .

G8 CHECK THE PINCH STRIP RETURN CIRCUIT FOR AN
OPEN
Yes
Measure the resistance between left pinch strip C4172-2, circuit No
RPR52 (VT/GY), harness side and LTM C4174B-8, circuit RPR52 REPAIR the circuit.
(VT/GY), harness side; and between right pinch strip C4173-2, CLEAR the DTCs.
circuit RPR52 (VT/GY), harness side and LTM C4174B-8, circuit REPEAT the LTM self-test.
RPR52 (VT/GY), harness side.

G9 CHECK THE DETENT AND FORKBOLT SWITCH PIDs
Yes
Enter the following diagnostic mode on the scan tool: DataLogger GO to G14 .
LTM .
PIDs: GO to G10 .
NOTE: The liftgate is in the primary position when the liftgate is in
the full closed position. The liftgate is in the unlatch position when
the liftgate is open and completely out of the striker. The liftgate
can be placed in the unlatched position by lifting up on the liftgate
handle.
Liftgate Latch
a
If detent switch is active in the fully unlatched position, manually
G10 CHECK THE OPERATION OF THE DETENT AND
FORKBOLT SWITCHES
Yes
ground at each of the connector pins and each latch position GO to G11 .
Liftgate Latch
(GY/YE) ohms a
(VT/OG)
(BU/GN)
(GY/YE)
(VT/OG) ohms
(BU/GN) ohms

G11 CHECK THE DETENT AND FORKBOLT SWITCH GROUND
CIRCUIT
Yes
Disconnect: Liftgate Latch/Unlatch Assembly C4339. GO to G12 .
ground. REPAIR the circuit.
CLEAR the DTCs.

G12 CHECK THE DETENT AND FORKBOLT SWITCH
Yes
Measure the resistance between power liftgate latch/unlatch GO to G13 .
REPAIR the circuit.
CLEAR the DTCs.

C4339-1 CPR64 C4174B-5
(VT/OG)
C4339-3 CPR65 C4174B-4
(BU/GN)
C4339-2 CPR66 C4174B-3
(GY/YE)

G13 CHECK THE DETENT AND FORKBOLT SWITCH
Yes
INSTALL a new power

LTM self-test.
No
Is the resistance greater than 10,000 ohms on all circuits? REPAIR the circuit.
CLEAR the DTCs.
G14 CHECK FOR CORRECT LTM OPERATION
Yes
correctly.
corroded connector.
CLEAR the DTCs.
Pinpoint Test H: The Power Liftgate Does Not Power Open (Power Close OK)
Normal Operation
If the power liftgate is in the closed position and the conditions are correct, the Liftgate/Trunk Module (LTM)
supplies 12 volts to the unlatch/cinching motor on circuit CPR62 (WH/BU), 12 volts to the clutch on circuit
CPR69 (BN/BU) and 12 volts to the motor on circuit CPR57 (GN/WH). As the liftgate is moving in the open
direction, the LTM monitors the position sensor for door speed to detect obstacles. Once the liftgate is
unlatched, the motor and clutch are activated to power open the liftgate.

Mechanical binding
LTM
PINPOINT TEST H: THE POWER LIFTGATE DOES NOT POWER OPEN (POWER CLOSE OK)

H1 CHECK THE MANUAL OPERATION OF THE
LIFTGATE
Yes
NOTE: If any other power liftgate related DTCs are GO to H2 .
present, diagnose those first before proceeding with
this pinpoint test. Refer to the Liftgate/Trunk Module No
(LTM) DTC Chart. If liftgate does not unlatch correctly,
Ignition ON.

Unlock all doors. If liftgate does not open and close

Turn the power liftgate OFF (disable) from the correctly, REFER to Liftgate in this
message center. section.
NOTE: A small amount of interference during a
manual operation will be amplified during a power
operation and may cause the liftgate to not power
open.
Manually open and close the liftgate.
Does the liftgate unlatch, open, close and latch
correctly?
H2 CHECK THE LIFTGATE LATCH AND STRIKER
ALIGNMENT
Yes
NOTE: Make sure to inspect the underside of the GO to Pinpoint Test A .
striker bridge for witness marks.
Inspect the striker and latch for correct alignment. No
Is the latch and striker aligned correctly? ALIGN the liftgate and striker. REFER
to Liftgate Alignment in this section.
TEST the system for normal operation.
Pinpoint Test I: DTC B117C
Normal Operation
The Liftgate/Trunk Module (LTM) monitors the sector gear open switch, circuit CPR67 (VT) and sector gear
close switch, CPR68 (YE) to determine the sector gear position.
DTC B117C (Latch Centering Switch Invalid) This DTC will set when the LTM detects the
sector gear open/close switch(es) are not in the correct state at the beginning of self-test.

LTM
PINPOINT TEST I: DTC B117C

I1 CHECK THE SECTOR GEAR SWITCH CIRCUITS
Yes
NOTE: If any other power liftgate related DTCs are present, GO to I4 .
diagnose those first before proceeding with this pinpoint test.
Refer to the Liftgate/Trunk Module (LTM) DTC Chart. No
GO to I2 .
Disconnect: Latch/Unlatch Assembly C4339.
PINPOINT TEST H: THE POWER LIFTGATE DOES NOT POWER OPEN (POWER CLOSE OK)157
Ignition ON.
Measure the voltage between power liftgate latch/unlatch
assembly C4339-4, circuit CPR67 (VT), harness side and
ground; and between C4339-6, circuit CPR68 (YE), harness
side and ground.
Is the voltage greater than 10 volts for both

measurements?
I2 CHECK CIRCUITS CPR67 (VT) AND CPR68 (YE) FOR A
SHORT TO GROUND
Yes
Ignition OFF. GO to I3 .
Measure the resistance between LTM C4174B-15, circuit No
CPR67 (VT), harness side and ground; and between LTM REPAIR the circuit. CLEAR the
C4174B-26, circuit CPR68 (YE), harness side and ground. DTCs. REPEAT the LTM
self-test.

I3 CHECK CIRCUITS CPR67 (VT) AND CPR68 (YE) FOR AN
OPEN
Yes
Measure the resistance between LTM C4174A, harness side CHECK the LTM connector for
and power liftgate latch/unlatch assembly C4339, harness bent or corroded connections on
side using the following chart: the component side and harness
CLEAR the DTCs. REPEAT the

LTM self-test.
LTM Circuit Assembly IF DTC B117C returns,
C4174A-15 CPR67 C4339-4 INSTALL a new LTM . REFER
(VT) to Liftgate/Trunk Module (LTM)
in this section. CLEAR the DTCs.
C4174A-26 CPR68 C4339-6 REPEAT the LTM self-test.
(YE)
No
PINPOINT TEST I: DTC B117C 158

REPAIR the circuit. CLEAR the

self-test.
Is the resistance less than 5 ohms for both measurements?

I4 CHECK CIRCUITS CPR67 (VT) AND CPR68 (YE) FOR A
SHORT TO VOLTAGE
Yes
Ignition OFF. REPAIR the circuit. CLEAR the
Disconnect: LTM C4174B. DTCs. REPEAT the LTM
Ignition ON. self-test.
Measure the voltage between power liftgate latch/unlatch
assembly C4339-4, circuit CPR67 (VT), harness side and No
ground; and between C4339-6, circuit CPR68 (YE), harness CHECK the power liftgate latch
side and ground. connector for bent or corroded
connections on the component
side and harness side. REPAIR as
necessary.

latch. REFER to Section 501-14 .
LTM self-test.
Is any voltage present for both measurements?
Pinpoint Test J: DTC B1317/B1318
NOTE: DTCs B1317 or B1318 can be set if the vehicle has been recently jump started, the battery has been
recently charged or the battery has been discharged. The battery may become discharged due to excessive
load(s) on the charging system from aftermarket accessories or if the battery has been left unattended with the
accessories on.
Normal Operation
The Liftgate/Trunk Module (LTM) continuously monitors the input voltage for correct operation. If the LTM
detects input voltage below 8 volts, it will store DTC B1318 in memory. If the LTM detects input voltage
greater than 16 volts, it will store DTC B1317 in memory. If the LTM sets DTC B1317 or B1318, it will
inhibit the power liftgate system operation.
DTC B1317 (Battery Voltage High) If the LTM detects voltage above 16 volts for greater than 3
seconds, it will set this DTC.
DTC B1318 (Battery Voltage Low) If the LTM detects voltage below 8 volts for greater than 3
seconds, it will set this DTC.


LTM
PINPOINT TEST J: DTC B1317/B1318
NOTE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection and
verification before proceeding with the pinpoint test.

J1 RETRIEVE ALL CMDTCs IN ALL MODULES
Yes
Ignition ON. REFER to Section 414-00 to diagnose the
Enter the following diagnostic mode on the scan charging system. CLEAR all Continuous
tool: Self Test ALL CMDTCs . Memory Diagnostic Trouble Codes
Is DTC B1317 or B1318 retrieved from one (CMDTCs). REPEAT the LTM self-test.
or more modules and P0563, P0620, P0626 or
P065B retrieved from the PCM? No
GO to J2 .
J2 TEST BATTERY CONDITION
Yes
Ignition OFF. If the battery passed the condition test but
Carry out the battery condition test. Refer to required a recharge, REFER to Section 414-00
Section 414-01 . to diagnose the charging system. CLEAR all
Did the battery pass the condition test? CMDTCs . REPEAT the LTM self-test.
If the battery passed the condition test and did

not require a recharge, GO to J3 .
No
INSTALL a new battery. CLEAR all CMDTCs
. REPEAT the LTM self-test.
J3 CHECK CHARGING SYSTEM VOLTAGE
Yes
NOTE: Do not allow the engine speed to For DTC B1318, GO to J4 .
increase above 2,000 rpm while performing this
step or the generator may self excite and result For DTC B1317, GO to J6 .
in default charging system output voltage. If
engine speed goes above 2,000 rpm, shut the No
vehicle OFF and restart the engine before REFER to Section 414-00 to diagnose the
performing this step. charging system. CLEAR all CMDTCs .
Measure the voltage of the battery:
For DTC B1317, turn off all accessories
and run the engine at 1,500 rpm for a
minimum of 2 minutes while measuring
battery voltage.
For DTC B1318, turn on headlights and
HVAC fan on high and run engine at
1,500 rpm for a minimum of 2 minutes
PINPOINT TEST J: DTC B1317/B1318 160

while measuring battery voltage.
Is the voltage between 13 and 15.2 volts?

J4 CHECK CIRCUITS SBB27 (BU/RD) AND
SBP14 (BN/RD) FOR VOLTAGE
Yes
Ignition OFF. GO to J5 .
Measure the voltage between LTM C4174A-4, No
circuit SBB36 (GN/RD), harness side and VERIFY Battery Junction Box (BJB) fuse 36
ground; and between LTM C4174A-9, circuit (30A) and Smart Junction Box (SJB) fuse 14
SBP14 (BN/RD), harness side and ground. (10A) are OK. If OK, REPAIR the circuit.
CLEAR the DTCs. REPEAT the LTM
self-test. If not OK, REFER to the Wiring
Diagrams manual to identify the possible
causes of the circuit short. CLEAR the DTCs.

measurements?
J5 CHECK CIRCUIT GD149 (BK/GY) FOR AN
OPEN
Yes
Measure the resistance between LTM GO to J6 .
C4174A-1, circuit GD149 (BK/GY), harness
side and ground. No

J6 CHECK FOR MODULE OPERATION
Yes
Check LTM C4174A for the following: INSTALL a new LTM module. REFER to
corrosion. Liftgate/Trunk Module (LTM) in this section.
damaged pins. REPEAT the LTM self-test.
PINPOINT TEST J: DTC B1317/B1318 161

pushed-out pins.
Connect LTM C4174A and make sure the No
connector seats correctly. The system is operating correctly at this time.
CLEAR all CMDTCs . The concern may have been caused by a loose
Operate the system to verify the concern is still or corroded connector. CLEAR the DTCs.
present. REPEAT the LTM self-test.
Pinpoint Test K: The Power Liftgate Does Not Operate Correctly Closes (With a Continuous
Chime) Immediately After a Power Open
Normal Operation
After the Liftgate/Trunk Module (LTM) has performed a power open operation, power is removed from the
clutch and drive motor. The LTM briefly continues to monitor the position of the liftgate. If excessive
movement in the closed direction is detected, power is reapplied to the clutch and a continuous chime is
initiated and remains on as the liftgate is automatically power closed.
If the excessive closing movement is detected on 11 successive power open requests, DTC B201A is set and
power liftgate operation is disabled until the DTC is cleared.
DTC 201A (Power System Disabled Due to High Manual Closing Speed) This DTC is set when
the LTM detects excessive closing movement on 11 successive power open requests. When DTC
201A is set, power liftgate operation is disabled until the DTC is cleared.

Excessive weight on the liftgate (for example: bike rack or snow and ice)
Power liftgate full open position not learned correctly during power liftgate initialization procedure
Liftgate assist cylinders
LTM
PINPOINT TEST K: THE POWER LIFTGATE DOES NOT OPERATE CORRECTLY CLOSES (WITH A
CONTINUOUS CHIME) IMMEDIATELY AFTER A POWER OPEN

K1 RETRIEVE ALL
CMDTCs IN ALL
MODULES
Yes
Ignition ON. CLEAR all Continuous Memory Diagnostic Trouble Codes (CMDTCs).
Enter the following GO to K2 .
diagnostic mode on
the scan tool: Self No
Test ALL GO to K2 .
CMDTCs .
Is DTC B201A
retrieved from the
LTM ?

K2 CHECK THE
LIFTGATE ASSIST
CYLINDERS
Yes
Verify there is no RE-INITIALIZE the power liftgate. REFER to Power Liftgate
excessive weight on Initialization in this section. TEST the system for normal operation.
the liftgate (for
example: bike rack or If DTC B201A returns or power liftgate still closes (with a continuous
snow and ice). chime) immediately after a power open, INSTALL a new LTM . REFER
Turn the power to Liftgate/Trunk Module (LTM) in this section. INITIALIZE the power
liftgate OFF (disable) liftgate. REFER to Power Liftgate Initialization in this section. TEST the
from the message system for normal operation.
center.
Operate the liftgate No
manually to verify INSTALL a new liftgate assist cylinders. RE-INITIALIZE the power
the liftgate assist liftgate. REFER to Power Liftgate Initialization in this section. TEST the
cylinders hold the system for normal operation.
liftgate open.
Did the liftgate
assist cylinders hold
the liftgate open
correctly?
PINPOINT TEST K: THE POWER LIFTGATE DOES NOT OPERATE CORRECTLY CLOSES
163(WITH A

Door Alignment - Front
All alignments
1. NOTE: Driver side shown, passenger side similar.
Remove the door latch striker plate.
Front door in and out, up and down alignment
2. Loosen, but do not remove, the front door hinge-to-front door fasteners enough to allow door
alignment.
Front door fore, aft and tilt alignment
3. Remove the front fender. For additional information, refer to Section 501-02 .
4. Loosen, but do not remove, the upper front door hinge-to-body fasteners enough to allow door
alignment.
Door Alignment - Front 164

5. Loosen, but do not remove, the lower front door hinge-to-body fasteners enough to allow door
alignment.
All alignments
6. Adjust the door. For additional information on door clearances, refer to Section 501-35 .
7. Tighten the door fasteners.

Tighten the front door hinge-to-front door fasteners to 30 Nm (22 lb-ft).
Tighten the front door hinge-to-body fasteners to 30 Nm (22 lb-ft).
8. Install and adjust the door striker as necessary. For additional information on door clearances, refer to
Section 501-35 .
Tighten the door latch striker plate bolts to 25 Nm (18 lb-ft).
Door Alignment - Front 165


Door Alignment - Rear
All alignments
1. NOTE: Driver side shown, passenger side similar.
Remove the door latch striker plate.
Rear door in and out, up and down alignment
2. Loosen, but do not remove, the rear door hinge-to-rear door fasteners enough to allow door alignment.
Front door fore, aft and tilt alignment
3. Remove the B-pillar trim panel. For additional information, refer to Section 501-05 .
4. Loosen, but do not remove, the rear door hinge-to-body nuts inside at the inside B-pillar enough to
allow door alignment.
All alignments
5. Adjust the door. For additional information on door clearances, refer to Section 501-35 .
Door Alignment - Rear 166

6. Tighten the door fasteners.
Tighten the rear door hinge-to-rear door fasteners to 30 Nm (22 lb-ft).
Tighten the rear door hinge-to-body fasteners to 30 Nm (22 lb-ft).
7. Install and adjust the door striker as necessary. For additional information on door clearances, refer to
Section 501-35 .
Tighten the door latch striker plate bolts to 25 Nm (18 lb-ft).
Door Alignment - Rear 167


Power Liftgate Initialization
NOTE: The power liftgate may not operate correctly under the following conditions:
A low voltage or dead battery

A disconnected battery
Repairs/adjustments have been made to the power liftgate rod, power liftgate motor, liftgate hinges or
liftgate striker
If any of these conditions has occurred, the power liftgate must be reinitialized.
1. NOTE: Battery power must be removed from the Liftgate/Trunk Module (LTM) for 20 seconds
before the LTM will enter the initialization mode.
Disconnect the battery or remove the LTM fuse(s).
2. Wait 20 seconds and reconnect the battery or reinstall the LTM fuse(s).
3. If liftgate is not already in the fully closed position, manually close and fully latch the power liftgate.
4. NOTE: Make sure the power liftgate system is turned ON in the message center before performing
this step.
NOTE: If the power liftgate does not open during this step, refer to the Symptom Chart to diagnose
the inoperative power liftgate.
Power open the power liftgate by using the key fob or control switch.
5. Once the power liftgate is fully open, close the power liftgate by using the key fob or control switch.
Power Liftgate Initialization 168


Liftgate Alignment
All alignments
1. Remove the liftgate striker.
Liftgate left and right alignment
2. Loosen, but do not remove, the hinge-to-liftgate bolts enough to permit movement of the liftgate.
Liftgate in and out, up and down alignment
3. Open the liftgate.
4. Position the top and sides of the liftgate opening weatherstrip aside.
5. Remove the D-pillar trim panels.
6. Remove the safety tethers from the rear of the headliner.
7. Remove the pin-type retainers from the rear of the headliner.
NOTICE: Use care to avoid bending or crimping the headliner.
8. Lower the rear of the headliner to gain access to liftgate hinge-to-body fasteners.
9. Loosen, but do not remove, the liftgate hinge-to-body fasteners enough to permit movement of the
liftgate.
All alignments
10. Adjust the liftgate. For additional information on liftgate clearances, refer to Section 501-35 .
11. Tighten the liftgate fasteners.

Tighten the liftgate hinge-to-body nuts to 23 Nm (17 lb-ft).
Tighten the liftgate hinge-to-body bolts to 30 Nm (22 lb-ft).
Tighten the liftgate hinge-to-liftgate bolts to 28 Nm (21 lb-ft).
12. Install the liftgate striker, adjust as necessary.

Tighten to 25 Nm (18 lb-ft).
13. For vehicles equipped with power liftgate, initialize the power liftgate. For additional information,
refer to Power Liftgate Initialization in this section.
Liftgate Alignment 169

Liftgate Alignment 170


Door
NOTE: Right front door shown, all other doors similar.

1 N806738 Door hinge-to-door bolts (4 required)
2 W702788 Door check arm-to-door bolts (2 required)
3 20124 RH/ 20125 LH Front door
3 24630 RH/ 24631 LH Rear door
1. Remove the door speaker. For additional information, refer to Section 415-00 .
2. Partially remove and position aside the door weather shield.
3. Disconnect the electrical connectors.

Disconnect the window switch electrical connector.
Disconnect the door lock switch electrical connector.
Disconnect the door speaker electrical connector.
If equipped, disconnect the outside rearview mirror switch electrical connector.
4. Remove the wiring harness from the door.
5. If equipped, remove the 2 door check arm-to-door bolts.
6. NOTE: An assistant is necessary for the removal of the door.
Remove the 4 door hinge-to-door bolts.
Door 171
Door 172

Door Check Arm

1 W702788 Door check arm-to-door bolt
2 - Door check arm nut
3 23552 Door check arm
Left and right sides
1. Remove the lower cowl trim panel.

Remove the door scuff plate.
Left side
2. Remove the parking brake control assembly and position aside. For additional information, refer to
Section 206-05 .
Left and right sides
3. Remove the lower cowl panel weather shield.
4. Remove the 2 door check arm-to-door bolts.
5. NOTE: Left side shown, right side similar.
Remove the 2 door check arm nuts.
6. Remove the door check arm from the opening in the lower cowl panel.
Door Check Arm 173

Door Check Arm 174


Liftgate
Material
Item Specification
Threadlock 262 WSK-M2G351-A6
TA-26
NOTE: Expedition shown, Navigator similar.

1 40400 Liftgate assembly
2 W713408 Liftgate strut ball studs
3 406A10 Liftgate struts
4 W712762 Liftgate hinge-to-liftgate bolts
5 42900 Liftgate hinges
6 W711238 Liftgate hinge-to body bolts
7 N621940 Liftgate hinge-to-body nuts
All vehicles
1. Remove the D-pillar panels. For additional information, refer to Section 501-05 .
Vehicles with safety canopies
2. Remove the 2 rear garment hangers.

Open the access panel.
Remove the garment hanger screws.
Vehicles without safety canopies
3. NOTICE: To prevent damage to the garment hanger retainer, use a 3/16-inch flat-blade
screwdriver for this step.
Liftgate 175
NOTE: The garment hanger is shown without the roof sheet metal to show the metal retainer clip.
The metal retainer clip will remain engaged in the sheet metal after the garment hanger is removed.
Remove the 2 rear garment hangers.
1. Open the access cover.

2. Insert the flat-blade screwdriver fully into the garment slot.
3. Rotate the screwdriver 90 degrees so that the screwdriver spreads the metal retainer clip.
Remove the plastic garment hanger.
All vehicles
4. Remove the headliner rear pin-type retainers and partially lower the rear of the headliner.
5. Disconnect the liftgate electrical connectors.
6. Remove the wire harness grommet and route the wire harness out from the roof.
7. Disconnect the rear washer tube.
8. Remove the rear washer tube grommet and route the rear washer tube out from the roof.
Liftgate 176
Vehicles with power liftgate
9. Remove the power liftgate rod-to-liftgate cover and nut.

10. Remove the power liftgate rod from the liftgate.

To install, apply threadlock to the threads of fastener and tighten to 11 Nm (97 lb-in).
All vehicles
11. NOTE: Left side shown, right side similar.
NOTE: An assistant is necessary for the removal of the liftgate.
Disconnect the assist cylinders at the side of the liftgate.
12. Remove the 4 liftgate hinge bolts and remove the liftgate.

If equipped with power liftgate, initialize the power liftgate system. For additional
information, refer to Power Liftgate Initialization in this section.
Liftgate 177
Liftgate 178

Liftgate/Trunk Module (LTM)

1 W506013 Liftgate/Trunk Module (LTM) retaining bolt
2 404D06 LTM
3 - LTM electrical connectors
1. Remove the rear quarter trim panel. For additional information, refer to Section 501-05 .
2. Remove the Liftgate/Trunk Module (LTM).

2. Remove the bolt.

Initialize the power liftgate. For additional information, refer to Power Liftgate Initialization
in this section.
Liftgate/Trunk Module (LTM) 179

Liftgate/Trunk Module (LTM) 180


Power Liftgate Rod
Material
Item Specification
TA-26
Part
Item Number Description
1 410B00 Power liftgate rod end cover
2 W520412 Power liftgate rod-to-liftgate retaining nut
3 - Power liftgate rod-to-motor retaining clip (part of the
power liftgate rod assembly)
4 - Power liftgate rod-to-bracket bolt
5 404B45 Power liftgate rod assembly
6 404E48 Power liftgate rod mounting stud
7 - Power liftgate rod bracket-to-pillar bolts (3 required)
8 - Power liftgate rod bracket (part of power liftgate rod
assembly)
1. Remove the LH quarter trim panel. For additional information, refer to Section 501-05 .
2. Unclip the power liftgate rod from the motor assembly.

Squeeze the clip as shown to release and position upward on the rod assembly.
Power Liftgate Rod 181

3. Remove the cover and the power liftgate rod-to-liftgate retaining nut.
To install, apply threadlock to the threads of fastener and tighten to 11 Nm (97 lb-in).
4. Remove the power liftgate rod-to-bracket bolt and the power liftgate rod assembly.

in this section.
Power Liftgate Rod 182


Power Liftgate Motor

1 W505425 Power liftgate motor retaining bolt
2 W520111 Power liftgate motor retaining nuts (2 required)
3 404C85 Power liftgate motor assembly
1. Remove the power liftgate rod assembly. For additional information, refer to Power Liftgate Rod in
this section.
2. Disconnect the power liftgate motor electrical connectors.
3. Remove the power liftgate retaining fasteners and the power liftgate motor assembly.

in this section.
Power Liftgate Motor 183

Power Liftgate Motor 184


Pinch Strip Switch

1 - Pinch strip electrical connector
2 42430B Pinch strip
NOTE: Left side shown, right side similar.
1. Remove the brake light.

Remove the screws.
2. Disconnect the pinch strip electrical connector.
3. Remove the pinch strip.

1. Remove the pin-type retainers.
2. Remove the grommet and route the harness out of the vehicle.
Pinch Strip Switch 185


SECTION 501-05: Interior Trim and Ornamentation 2011 Expedition, Navigator Workshop Manual

A-pillar assist handle bolts 5 - 44
B-pillar and C-pillar trim panel bolts 8 - 71
C-pillar trim panel nuts 8 - 71
Power liftgate rod-to-liftgate nut 11 - 97
Rear assist handle bolt 8 - 71
Safety belt anchor bolts 40 30 -
Safety belt guide bolts 40 30 -
Sun visor screws 2 - 18

Interior Trim - Exploded View
NOTE: Expedition/Navigator shown, Expedition EL/Navigator L similar.

1 31458 A-pillar assist handle bolt cover (2 required)
2 W709040 A-pillar assist handle bolt (2 required)
3 31406A A-pillar assist handle
4 03598 A-pillar trim panel
5 N611176 Rear assist handle bolt (2 required)
6 31406B Rear assist handle
7 248A55 B-pillar trim panel bolt cover
8 N808544 B-pillar trim panel bolt
9 243A52B B-pillar upper trim panel
10 243A52A B-pillar lower trim panel
11 248A55 C-pillar trim panel fastener cover
12 N808544 C-pillar trim panel bolt
12 - C-pillar trim panel nut (Expedition EL/Navigator L)
13 31004 C-pillar trim panel
14 31010 D-pillar trim panel
15 13228A Rear door scuff plate
16 13208 Front door scuff plate
17 02348 Cowl panel side trim
18 023A98 Cowl panel cover
Interior Trim - Exploded View 188

Interior Trim - Exploded View 189

A-Pillar Trim Panel
1. Remove the 2 A-pillar assist handle bolt covers.
2. Remove the 2 A-pillar assist handle bolts.

3. NOTE: Carefully rotate the A-pillar trim panel during this step.
Remove the A-pillar trim panel.
Pull the A-pillar trim panel outward to release the A-pillar retaining clips.
4. NOTICE: To avoid damage to the A-pillar trim panel, remove any retaining clips from the body
and attach them to the A-pillar trim panel before installing.
A-Pillar Trim Panel 190

B-Pillar Trim Panel
Upper and lower
1. Move the front seat to the full forward position.
2. NOTE: Position the shoulder safety belt guide to the lowest position.
NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide
cover is damaged or the cover does not remain closed, install a new shoulder safety belt guide cover.
Remove the shoulder safety belt guide cover.
Detach the top of the shoulder safety belt guide cover.

Rotate the shoulder safety belt guide cover 90 degrees and remove from the safety belt guide
bolt.
3. Remove the shoulder safety belt guide.

Remove the shoulder safety belt guide bolt.
Remove the shoulder safety belt guide.
4. NOTICE: To avoid damage to the upper B-pillar trim panel, remove any retaining clips from
the body and attach them to the upper B-pillar trim panel before installing.
Remove the upper B-pillar trim panel.
1. Remove the bolt cover and bolt.

2. Remove the upper B-pillar trim panel by pulling outward to release the clips.
B-Pillar Trim Panel 191

Lower
5. Remove the front and rear door scuff plates.
6. NOTICE: To avoid damage to the lower B-pillar trim panel, remove any retaining clips from
the body and attach them to the lower B-pillar trim panel before installing.
Pull outward to release the lower B-pillar trim panel clips and reposition the lower B-pillar trim panel.
7. Remove the front safety belt anchor bolt.

8. Feed the safety belt through the lower B-pillar trim panel and remove.
Upper and lower

When installing the upper B-pillar trim panel, insert the safety belt guide slide into the upper
B-pillar trim panel.


C-Pillar Trim Panel
All vehicles
1. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide
cover is damaged or the cover does not remain closed, install a new shoulder safety belt guide cover.
1. Position the shoulder safety belt cover upward.

2. Remove the safety belt guide bolt.
2. Detach the safety belt holder pin-type retainer.
3. Remove the C-pillar trim panel fastener cover.
Expedition EL/Navigator L only
4. Remove the C-pillar trim panel nut.

All vehicles except Expedition EL/Navigator L
5. Remove the C-pillar trim panel bolt.
C-Pillar Trim Panel 194

All vehicles
6. NOTICE: To avoid damage to the C-pillar trim panel, remove any retaining clips from the body
and attach them to the C-pillar trim panel before installing.
Remove the C-pillar trim panel.
Pull the C-pillar trim panel outward to release the C-pillar trim panel retaining clips.
C-Pillar Trim Panel 195

D-Pillar Trim Panel
NOTE: Right side with power vent windows shown, all others similar.
1. NOTE: Inspect the shoulder safety belt guide cover for damage. If the shoulder safety belt guide
cover is damaged or cover does not remain closed, install a new shoulder safety belt guide cover.
1. Position the shoulder safety belt guide cover upward.

2. Remove the shoulder safety belt guide bolt.
All vehicles
2. Remove the rear upper headliner trim panel.

Pull the rear upper headliner trim panel downward to release the retaining clips.
3. NOTICE: To avoid damage to the D-pillar trim panel, remove any retaining clips from the body
and attach them to the D-pillar trim panel before installing.
Remove the D-pillar trim panel.
1. Disengage the upper clip by pulling downward.

2. Unseat the D-pillar trim panel and rotate forward to remove.
If equipped, disconnect the speaker electrical connector.
D-Pillar Trim Panel 196

D-Pillar Trim Panel 197

Quarter Trim Panel
NOTE: Navigator shown, Expedition, Expedition EL and Navigator L similar.

1 13560A Cup holder
2 13530A Utility tray
3 19N236B Power point
4 - Pin-type retainer
5 601B32 Cover
6 31012A/ 31012B Rear quarter trim panel
All vehicles
1. Remove the C-pillar trim panel. For additional information, refer to C-Pillar Trim Panel in this
section.
2. Remove the D-pillar trim panel. For additional information, refer to D-Pillar Trim Panel in this
section.
3. NOTICE: To avoid damage to the liftgate scuff plate, remove any retaining clips from the body
and attach them to the liftgate scuff plate before installing.
Remove the liftgate scuff plate.
Lift the liftgate scuff plate upward to release the liftgate scuff plate retaining clips.
Quarter Trim Panel 198

4. Remove the rear floor cargo space trim panel.
5. Remove the floor jack assembly.
Expedition EL/Navigator L
6. Remove the cargo space trim panel.

1. Move the cargo shelf to the upright position.
2. Remove the cargo space trim panel.
7. NOTE: RH cargo shelf bracket shown, LH similar.
Remove the LH and RH cargo shelf bracket bolts.
All vehicles
8. Remove the pin-type retainers and position aside the carpeting.

9. Remove the cargo space panel.

Remove the LH and RH bolts.
Remove the cargo space panel by pulling upward.
10. Remove the third row seat safety belt anchor bolt.
11. Remove the rear quarter trim panel pin-type retainer.
12. Remove the third row seat safety belt anchor and scrivet.
Remove the third row seat safety belt anchor bolt.
13. Remove the rear quarter trim panel bolt.
14. Open the third row safety belt anchor bolt cover.

16. Remove the third row safety belt.
All vehicles
17. Remove the rear door scuff plate by pulling upward.
18. Remove the second row safety belt anchor.

Remove the second row safety belt anchor bolt.
19. Fold the seat back of the third row seat to the full downward position.
20. NOTICE: To avoid damage to the quarter trim panel, remove any retaining clips from the body
and attach them to the quarter trim panel before installing.
Remove the rear quarter trim panel.
Disengage the rear clip on the base of the trim panel first, by pulling the bottom rear edge
toward the center of the vehicle.
Disengage the remaining clips.
If equipped, disconnect the electrical connectors.


Door Trim Panel - Front
NOTE: Expedition shown, Navigator, Expedition EL and Navigator L similar.

1 W505156 Door handle screw
2 237W10 Front door trim panel finish cover
3 W505156 Door trim panel armrest screw (2 required)
4 W708412 Door trim panel screw
5 W708392 Lower door trim panel screws (2 required)
6 23942 RH/ 23943 LH Front door trim panel
7 7822670 Door handle trim bezel
8 78237W10 Door handle screw cover
NOTE: Left front door shown, right front door similar.
1. Remove the door handle screw cover.

Use the service notch.
2. Remove the door handle screw.
3. Remove the door handle trim bezel.
4. Remove the front door trim panel finish cover.
5. Remove the 2 door trim panel armrest screws.
6. Remove the door trim panel screw.
Remove the 2 lower door trim panel screws.
8. Disengage the sail panel clip.
Door Trim Panel - Front 203

9. NOTICE: To avoid damage to the door trim panel, lift the door trim panel by pulling directly
upward on the armrest to disengage the panel clips.
Remove the front door trim panel.
Door Trim Panel - Front 204

Door Trim Panel - Rear
NOTE: Expedition shown, Navigator, Expedition EL and Navigator L similar.

1 W505156 Door handle screw
2 237W10 Rear door trim panel finish cover
3 W505156 Door trim panel armrest screw (2 required)
4 W708412 Door trim panel screw
5 W708392 Lower door trim panel screws (2 required)
6 27406 RH/ 27407 LH Rear door trim panel
7 78275A18 Door handle trim bezel
8 78237W10 Door handle screw cover
NOTE: Left rear door shown, right rear door similar.
1. Remove the door handle screw cover.

Use the service notch.
2. Remove the door handle screw.
3. Remove the door handle trim bezel.
4. Remove the rear door trim panel finish cover.
5. Remove the 2 door trim panel armrest screws.
6. Remove the door trim panel screw.
8. NOTICE: To avoid damage to the door trim panel, lift the door trim panel by pulling directly
upward on the armrest to disengage the panel clips.
Remove the rear door trim panel.
Door Trim Panel - Rear 205

Door Trim Panel - Rear 206

Liftgate Trim Panel
NOTE: Non-power liftgate shown, power liftgate similar.

1 W706264 Scrivets (2 required)
2 42410 Upper liftgate trim panel
3 N807378 Liftgate assist handle screw (2 required)
4 434A14 Liftgate assist handle
5 46404 Lower liftgate trim panel
6 W701882 Retaining clip (12 required)
All vehicles
1. Open the liftgate glass and remove the 2 scrivets.
Vehicles with power liftgate
2. Remove the power liftgate rod-to-liftgate cover and nut.

Liftgate Trim Panel 207

3. Remove the power liftgate rod from the liftgate.
All vehicles
4. Remove the upper liftgate trim panel.

Pull the lower corners toward the center on both sides and pull down along the top.
5. Remove the liftgate assist handle.

1. Remove the 2 liftgate assist handle screws.
2. Remove the liftgate assist handle.
6. NOTICE: To avoid damage to the liftgate trim panel, remove any retaining clips from the body
and attach them to the liftgate trim panel before installing.
NOTE: The back of the liftgate trim panel shown, with the location of the liftgate trim panel retainers
indicated.
Remove the lower liftgate trim panel.
Pull the lower liftgate trim panel at the center to release the center retaining clips.
Release the remaining retaining clips 2 to 3 at a time, starting from the right side and working
to the left side.
When all of the retaining clips are released, slide the liftgate trim panel forward and down,
away from the liftgate.


Power Point
Special Tool(s)
Remover, Power Point Socket

501-039 or equivalent
Removal
NOTE: Power point cover may differ depending on location.
1. Open the power point cover.
2. Install the Power Point Socket Remover in one of the power point socket slots.
3. Position the Power Point Socket Remover so that it engages in the adjacent slot.
4. Using the Power Point Socket Remover, pull the power point socket out of the retainer.
5. Disconnect the electrical connector.
Installation
1. Connect the electrical connector.
2. Slide the power point socket into the retainer.
Power Point 210

Power Point 211

Headliner

1 17C712 Front headliner wiring harness
2 - Sun visor screw
3 - Sun visor screw (3 required)
4 04104 Sun visor
5 - Auxiliary sun visor
6 29024 Garment hangers (4 required)
7 50908B Center pin-type retainers (2 required)
8 50908A Lower pin-type retainers (2 required)
9 13A409 Rear headliner wiring harness
10 51944 Headliner
All vehicles
1. Position aside the front and rear door weatherstrips.
2. If equipped, remove the roof opening panel trim ring.
Headliner 212
3. Remove the LH and RH A-pillar trim panels. For additional information, refer to A-Pillar Tril in this
section.
4. Remove the 2 wiring harness pin-type retainers from the A-pillar.
5. Open and fully lower the glove compartment.

Release the glove compartment tabs.
6. If equipped, disconnect the satellite radio antenna.
7. Remove the pin-type retainer and disconnect the electronic compass/auto-dimming rear view mirror
electrical connector.
8. If equipped, separate the satellite antenna cable from the wiring harness.
9. If equipped, remove the electronic compass sensor.
10. If equipped, disconnect the auto-dimming mirror electrical connector.
Headliner 213
11. Remove the LH and RH sun visors.

Remove the 6 sun visor screws.
12. Remove the LH and RH sun visor clips.

Remove the 2 sun visor clip screws.
13. If equipped, remove the overhead console.

Pull the overhead console downward to release the overhead console retaining clips.
14. If equipped, remove the DVD player. For additional information, refer to Section 415-00 .
15. Remove the LH and RH B-pillar trim panels. For additional information, refer to B-Pillar Trim Panel
in this section.
16. Remove the LH and RH C-pillar trim panels. For additional information, refer to C-Pillar Trim Panel
in this section.
17. Remove the LH and RH D-pillar trim panels. For additional information, refer to D-Pillar Trim Panel
in this section.
Vehicles with safety canopies
18. Remove the 4 garment hangers.

Open the access panel.
Remove the garment hanger screws.
Vehicles without safety canopies
19. NOTICE: To prevent damage to the garment hanger retainer, use a 3/16-inch flat-blade
screwdriver for this step.
NOTE: The garment hanger is shown without the roof sheet metal to show the metal retainer clip.
The metal retainer clip will remain engaged in the sheet metal after the garment hanger is removed.
Remove the 2 garment hangers.
1. Open the access cover.

2. Insert the flat-blade screwdriver fully into the garment slot.
3. Rotate the screwdriver 90 degrees so that the screwdriver spreads the metal retainer clip.
Remove the plastic garment hanger.
Headliner 214
20. Open the third row safety belt anchor bolt cover.
22. Remove the third row safety belt.
All vehicles
23. Remove the 2 center pin-type retainers.
24. Remove the 2 rear pin-type retainers.
Vehicles with rear climate control
25. Tilt the headliner to release the vent duct.
All vehicles
26. Disconnect the rear electrical connector.
Headliner 215
27. NOTICE: To avoid bending or crimping the headliner, the help of an assistant is required for
this step.
Remove the headliner.

Transfer parts as necessary.
Headliner 216
SECTION 501-08: Exterior Trim and Ornamentation 2011 Expedition, Navigator Workshop Manual

Power Running Board (PRB) step screws 12 - 106
Running board retaining bolts 23 17 -
Headliner 217
Exterior Trim
The exterior trim and ornamentation consists of the:
rear door finish panel.

body side opening moulding.
front fender wheel opening moulding.
grille assembly.
front fender side finish panel.
front door side finish panel.
front door window outside rear moulding.
body side window outside front moulding.
running boards.
Power Running Boards (PRBs) (if equipped).
PRB motor.
PRB brackets (regular wagon).
PRB brackets (extended wagon)
PRB module.
PRB step.
If equipped, the PRBs automatically move when the doors are opened to assist entering and exiting the
vehicle.
The PRB feature may be enabled/disabled through the message center. For information on how to access the
PRB feature within the message center, refer to the Owner's Literature.
When the PRB is disabled (OFF), the PRB will immediately move to the stowed position regardless of the
position of the doors.
When the PRB is enabled (AUTO), the PRBs will extend when the doors are opened and return to the stowed
position when the doors are closed or vehicle speed is greater than 8 km/h (5 mph).
When the PRBs are manually set to the deployed position (OUT), they will return to the stowed position and
AUTO mode when the vehicle speed is greater than 8 km/h (5 mph).
Exterior Trim 218

Exterior Trim 219

Power Running Board (PRB)
Special Tool(s)


Principles of Operation
The Power Running Boards (PRBs) are controlled by the Power Running Board (PRB) module. The PRB
motors receive motor power and ground from the PRB module. The PRB module receives door ajar switch
status and vehicle speed information from the Controller Area Network (CAN).
When in AUTO mode, the PRBs will deploy when a door on the same side of the vehicle is opened. When
both doors on the same side are closed, the PRBs will retract.
When in OUT mode, both PRBs will stay deployed until OUT mode is deselected, reset to AUTO mode or
vehicle speed is greater than 8 km/h (5 mph). Mode will automatically switch back to AUTO once above 8
km/h (5 mph).
When an obstacle is detected, the PRB will reverse direction. If a second obstacle is detected, the PRB will
reverse direction again. If a third obstacle is detected, the PRB will stop against the third obstacle until the
following conditions are met:
Change in door ajar status

Change in the message center status (AUTO, OUT, OFF)
Vehicle speed greater than 8 km/h (5 mph)
2. Visually inspect for obvious signs of mechanical or electrical damage.
Power Running Board (PRB) 220

Power Running Battery Junction Box (BJB) fuse 11

Board (PRB) (40A)


refer to Section 418-00 to diagnose no response from the PRB module.

418-00 .
(CMDTCs).
8. Clear the CMDTCs and carry out the self-test diagnostics for the PRB module.
9. If the DTCs retrieved are related to the concern, go to Power Running Board (PRB) Module DTC
Chart. For all other DTCs, refer to Section 419-10 .
DTC Chart
Power Running Board (PRB) Module DTC Chart

B1162 Power Running Board Hall GO to Pinpoint Test E .
Effect Sensor Power Circuit
Short to Battery
B1163 Left Power Running Board GO to Pinpoint Test E .
Hall Effect Sensor Failure
B1164 Power Running Board Hall GO to Pinpoint Test E .
Effect Sensor Power Circuit
Short To Ground
B1167 GO to Pinpoint Test D .

Left Power Running Board

Deploy and/or Stow Circuit
Short To Battery
B1168 Left Power Running Board GO to Pinpoint Test D .
Motor Circuit Short To
Ground
B1169 LH Motor Traveled Too Far LH motor is freewheeling (broken geartrain linkage). INSTALL a
new LH Power Running Board (PRB) motor. REFER to Power
Running Board (PRB) Motor in this section.
B116A RH Motor Traveled Too Far RH motor is freewheeling (broken geartrain linkage). INSTALL a
new RH PRB motor. REFER to Power Running Board (PRB) Motor
in this section.
B116B LH Power Running Board GO to Pinpoint Test D .
Motor Short
B116C RH Power Running Board GO to Pinpoint Test D .
Motor Short
B116D LH Power Running Board GO to Pinpoint Test D .
Motor Line Open
B116E RH Power Running Board GO to Pinpoint Test D .
Motor Line Open
B1170 Right Power Running Board GO to Pinpoint Test E .
Hall Effect Sensor Failure
B1171 Left Power Running Board INSTALL a new LH PRB motor. REFER to Power Running Board
Hall Effect Signal Noisy (PRB) Motor in this section.
B1172 Right Power Running Board INSTALL a new RH PRB motor. REFER to Power Running Board
Hall Effect Signal Noisy (PRB) Motor in this section.
B1175 Right Power Running Board GO to Pinpoint Test D .
Motor Circuit Short To
Ground
B1178 Right Power Running Board GO to Pinpoint Test D .
Deploy and/or Stow Circuit
Short To Battery
B1317 Battery Voltage High GO to Pinpoint Test F .
B1318 Battery Voltage Low GO to Pinpoint Test F .
B1342 ECU is Faulted INSTALL a new PRB module. REFER to Power Running Board
(PRB) Module in this section.
B2139 Data Mismatch (receive data REFER to Section 419-10 .
does not match what was
expected)
B2813 LH Power Running Board GO to Pinpoint Test B .
Stow Time Fail
B2814 LH Power Running Board GO to Pinpoint Test B .
Deploy Time Fail
B2816 RH Power Running Board GO to Pinpoint Test F .
Stow Time Fail
B2817 RH Power Running Board GO to Pinpoint Test C .
Deploy Time Fail
U1900 CAN Communication Bus Do not install a new PRB module as part of the repair for a PRB DTC
Fault - Receive Error U1900 fault. The PRB is not the source of the fault when DTC U1900

is present. REFER to Section 418-00 to diagnose the Medium Speed

Controller Area Network (MS-CAN) concern.
U2050 No Application Present INSTALL a new PRB module. REFER to Section 419-10 . REPEAT
the self-test.
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test A: The PRB Does Not Operate Correctly - Both Running Boards
Refer to Wiring Diagrams Cell 109 , Power Liftgate/Retractable Running Boards for schematic and connector
information.
NOTE: The Power Running Board (PRB) module will stop functionality when battery voltage drops below
9.5 volts (early build) or 9.0 volts (late build). The PRB system will recover at the next door ajar transition,
provided that the battery voltage remains above 9.0 volts (late build only).
Normal Operation
The PRB module receives power through circuit SBB11 (BU/RD) and ground through circuit GD143
(BK/VT). The LH and RH PRB motor Hall-effect sensors receive a regulated 10-volt power supply from the
PRB module through circuit CPR47 (GY/BN). The Hall-effect ground is provided by the PRB module
through circuit RPR47 (BU/GN). The PRB module receives door ajar and vehicle speed status over the
Controller Area Network (CAN).

Fuse
PCM
Instrument Cluster (IC)
PRB module
PINPOINT TEST A: THE PRB DOES NOT OPERATE CORRECTLY - BOTH RUNNING BOARDS
Result / Action to
Test Step
Take
A1 RETRIEVE ALL CMDTCs IN ALL MODULES
Yes
Ignition ON. REFER to Section
Enter the following diagnostic mode on the scan tool: Self-Test - ALL 419-10 to diagnose
CMDTCs . the door ajar
Are any door ajar switch or vehicle speed related DTCs present? switch or vehicle
speed related
DTCs.

No
GO to A2 .
A2 CHECK THE OPERATION OF THE PRBs - AUTOMATIC MODE
Yes
Set the PRB system to the AUTO (enabled) mode, where the boards The system is
automatically deploy when a door on the same side is opened and retract operating as
when the door is closed. designed.
Open and close the LH front door. The LH PRB should deploy when the REVIEW
door is open and retract when the door is closed. operation of the
Open and close the LH rear door. The LH PRB should deploy when the door PRB system with
is open and retract when the door is closed. the customer.
Open and close the RH front door. The RH PRB should deploy when the
door is open and retract when the door is closed. No
Open and close the RH rear door. The RH PRB should deploy when the door GO to A3 .
is open and retract when the door is closed.
Did both span title="Power Running Boards" class="popup"
onmouseover="this.className='popupnounderline';"
onmouseout="this.className='popup';">PRBs operate correctly, with
no reversal of motion or noise while in motion?
A3 CHECK THE OPERATION OF THE PRBs - MANUAL MODE
Yes
Set the PRB system to the OUT mode, where the boards are deployed all the GO to A5 .
time, regardless of door open/closed status and vehicle speed is less than 8
km/h (5 mph). No
Did both PRBs deploy? GO to A4 .
A4 CHECK THE PRBs FOR FOREIGN MATERIAL
Yes
NOTE: If the system has false bounce back, stops in mid-travel, is noisy or The system is
will not deploy or stow completely, check to see if any foreign material is operating
caught in the PRB hinge points, step area or door sill. If foreign material is normally. The
found, clean the PRB hinge points, step area and door sill with a concern may have
high-pressure washer. If the system operates correctly after cleaning, refer been caused by
the customer to the Owner's Literature for correct cleaning instructions. foreign material or
Check the PRB hinge points, step area and door sill of the LH and RH PRBs blockage in the
for foreign material or blockage. If any foreign material or blockage is PRB hinge points,
found, remove it, and if necessary, set the PRB system to the OUT mode and step area or door
clean the PRB hinge points, step area and door sill with a high-pressure sill. REFER the
washer. Avoid direct spray to the motor. customer to the
Set the PRB system to the AUTO (enabled) mode, where the boards Owner's Literature
automatically deploy when a door on the same side is opened, and retract for correct
when the door is closed. cleaning
Open and close the LH front door. The LH PRB should deploy when the instructions.
door is open, and retract when the door is closed.
Open and close the RH front door. The RH PRB should deploy when the No
door is open, and retract when the door is closed. GO to A5 .
Does the PRB system operate normally during all test steps?
A5 VERIFY THE DOOR AJAR SWITCH OPERATION
Yes
Open and close each door, verify the interior lights operate correctly and GO to A6 .
door ajar is noted on the vehicle message center.
Do the interior lights turn ON when the door is opened and OFF when No
the door is closed? REFER to Section
224
417-02 to diagnose
the interior
lighting concern
before attempting
to diagnose the
PRB concern.
A6 CHECK THE HALL-EFFECT SENSOR POWER AND GROUND
Yes
Disconnect: PRB LH Motor C3185. GO to A13 .
Disconnect: PRB RH Motor C3186.
Ignition ON. No
Measure the voltage between RH PRB motor C3186-2, circuit CPR47 If the voltage was
(GY/BN), harness side and C3186-6, circuit RPR47 (BU/GN), harness side. less than 7 volts,
GO to A7 . If the
voltage was
greater than 10.5
volts, GO to A12 .
Open RH door.
Voltage signal will only be present for less than one second.
A7 CHECK HALL-EFFECT SENSOR POWER CIRCUIT FOR VOLTAGE
Yes
Measure the voltage between RH PRB motor C3186-2, circuit CPR47 GO to A11 .
(GY/BN), harness side and ground.
No
GO to A8 .
Open RH door.
A8 CHECK HALL-EFFECT SENSOR POWER CIRCUIT FOR AN OPEN
OR SHORT TO GROUND
Yes
Disconnect: PRB Module C3313B.
Measure the resistance between RH PRB motor C3186-2, circuit CPR47 No
(GY/BN), harness side and PRB module C3313B-5, circuit CPR47 (GY/BN) REPAIR the
harness side; and between RH PRB motor C3186-2, circuit CPR47 circuit. CLEAR
(GY/BN), harness side and ground. the DTCs.
REPEAT the
self-test.
225
Is the resistance less than 5 ohms between the PRB motor and PRB
module; and greater than 10,000 ohms between the PRB motor and
ground?
A9 CHECK THE PRB MODULE POWER CIRCUIT FOR VOLTAGE
Yes
Measure the voltage between PRB module C3313B-1, circuit SBB11 GO to A10 .
(BU/RD), harness side and ground.
No
VERIFY Battery
Junction Box
(BJB) fuse 11
(40A) is OK. If
OK, REPAIR the
circuit. CLEAR
the DTCs.
REPEAT the
self-test.
Is battery voltage present?
If not OK, REFER
to the Wiring
Diagrams manual
to identify the
possible causes of
the circuit short.
REPAIR the
circuit. CLEAR
the DTCs.
REPEAT the
self-test.
A10 CHECK THE PRB MODULE GROUND CIRCUIT FOR AN OPEN
Yes
Measure the resistance between the PRB module C3313B-4, circuit GD143
(BK/VT), harness side and ground. No
REPAIR the
circuit. CLEAR
the DTCs.
REPEAT the
self-test.
226
A11 CHECK THE HALL-EFFECT SENSOR GROUND CIRCUIT FOR AN

OPEN
Yes
Measure the resistance between RH PRB motor C3186-6, circuit RPR47 No
(BU/GN), harness side and PRB module C3313B-14, circuit RPR47 REPAIR the
(BU/GN), harness side. circuit. CLEAR
the DTCs.
REPEAT the
self-test.

A12 CHECK THE HALL-EFFECT SENSOR POWER CIRCUIT FOR A
SHORT TO VOLTAGE
Yes
Ignition OFF. REPAIR the
Disconnect: PRB Module C3313B. circuit. CLEAR
Ignition ON. The DTCs.
Measure the voltage between RH PRB motor C3186-2, circuit CPR47 REPEAT the
(GY/BN), harness side and ground. self-test.
No
GO to A13 .

A13 CHECK THE PRB MODULE FOR CORRECT OPERATION
Yes
Connect: PRB LH Motor C3185. INSTALL a new
Connect: PRB RH Motor C3186. PRB module.
Visually inspect all PRB module connectors. REFER to Power
Check for: Running Board
corrosion. (PRB) Module in
pushed-out pins. this section.
Connect all PRB module connectors and make sure they seat correctly. CLEAR the DTCs.
Operate the system and verify the concern is still present. REPEAT the
Is the concern still present? self-test.
No
The system is
operating correctly
at this time.
227
Concern may have

been caused by a
loose or corroded
connector.
CLEAR the DTCs.
REPEAT the
self-test.
Pinpoint Test B: The Power Running Board (PRB) Does Not Operate Correctly - Left Running Board
Does Not Deploy/Stow or Reverses Direction
information.
Normal Operation
The Power Running Board (PRB) module receives door ajar and vehicle speed status over the Controller Area
Network (CAN). During LH PRB deployment, the PRB module supplies power to the LH PRB motor through
circuit CPR41 (BU/WH) and ground through circuit CPR42 (WH). The PRB module stows the LH PRB by
supplying power to the LH PRB motor through circuit CPR42 (WH) and ground through circuit CPR41
(BU/WH). The PRB module provides a regulated 10-volt power supply to the Hall-effect sensor (internal to
the PRB motor) through circuit CPR47 (GY/BN). The Hall-effect ground is provided by the PRB module
through circuit RPR47 (BU/GN). The PRB module monitors the LH PRB Hall-effect signal through circuit
VPR43 (GY/BU). If the PRB module does not receive any signal from the Hall-effect sensor during operation,
the PRB will stop.
DTC B2813 (LH Power Running Board Stow Time Fail) - When the left running board takes greater
than 4 seconds to stow.
DTC B2814 (LH Power Running Board Deploy Time Fail) - When the left running boaakes greater
than 4 seconds to deploy.

Door ajar switch
PRB module
LH PRB motor
LH rear PRB bracket (regular wagon)
PINPOINT TEST B: THE POWER RUNNING BOARD (PRB) DOES NOT OPERATE CORRECTLY - LEFT RUNNING
BOARD DOES NOT DEPLOY/STOW OR REVERSES DIRECTION

B1 CHECK THE OPERATION OF THE PRB - AUTOMATIC
MODE
Yes
Set the PRB system to the AUTO (enabled) mode, where the The system is operating as
boards automatically deploy when a door on the same side is designed. REVIEW operation of
opened, and retract when the door is closed. the PRBs system with the
Open and close the LH front door. The LH PRB should deploy customer.
when the door is open, and retract when the door is closed.
No

Open and close the LH rear door. The LH PRB should deploy GO to B2 .
Open and close the RH front door. The RH PRB should deploy
Open and close the RH rear door. The RH PRB should deploy
Did both PRB operate correctly, with no reversal of
motion, or noise while in motion?
B2 CHECK THE OPERATION OF THE PRBs - MANUAL
MODE
Yes
Set the PRB system to the OUT mode, where the boards are GO to B6 .
deployed all the time, regardless of door open/closed status and
vehicle speed is less than 8 km/h (5 mph). No
Did both PRBs deploy? GO to B3 .
B3 CHECK THE PRBs FOR FOREIGN MATERIAL
Yes
NOTE: If the system has false bounce back, stops in The system is operating
mid-travel, is noisy or will not stow completely, extend the normally. The concern may
PRB and check to see if any foreign material is caught in the have been caused by foreign
PRB hinge points, step area or door sill. If foreign material is material or blockage in the PRB
found, clean the PRB hinge points, step area and door sill with hinge points, step area or door
a high-pressure washer. If the system operates correctly after sill. REFER the customer to the
cleaning, refer the customer to the Owner's Literature for Owner's Literature for correct
correct cleaning instructions. cleaning instructions.
Check the PRB hinge points, step area and door sill of the LH
PRB for foreign material or blockage. If any foreign material No
or blockage is found, remove it, and if necessary, set the PRB GO to B4 .
system to the OUT mode and clean the PRB hinge points, step
area and door sill with a high-pressure washer. Avoid direct
spray to the motor.
Set the PRB system to the AUTO (enabled) mode, where the
boards automatically deploy when either door on the same side
is opened, and retract when the door is closed.
Open and close the LH front door. The LH PRB should deploy
when the door is open and retract when the door is closed.
Does the LH PRB operate normally during all test steps?
B4 CHECK REAR PRB BRACKET FOR BINDING (REGULAR
WAGON ONLY)
Yes
Regular wagon only, remove the PRB step. Refer to Power INSTALL a new rear PRB
Running Board (PRB) Step in this section. bracket. REFER to Power
Manually operate the rear PRB bracket by hand. Running Board (PRB) Bracket
Does the rear PRB bracket bind? in this section. TEST system for
normal operation.
No
GO to B5 .
B5 CHECK IF DTCs ARE PRESENT
Yes
Use the recorded PRB module DTCs from the continuous and INSTALL a new PRB motor.
on-demand self test. REFER to Power Running
PINPOINT TEST B: THE POWER RUNNING BOARD (PRB) DOES NOT OPERATE CORRECTLY
229- LEFT R
Is DTC B2813 or B2814 present? Board (PRB) Motor in this

section. CLEAR the DTCs.
REPEAT the self-test.
No
GO to B7 .
B6 VERIFY THE DOOR AJAR OPERATION
Yes
Open and close the LH front and LH rear door, and verify the GO to B7 .
interior lights operate correctly and door ajar is noted on the
vehicle message center. No
Do the interior lights turn ON when the door is opened, REFER to Section 417-02 to
and OFF when the door is closed? diagnose the interior lighting
concern before attempting to
diagnose the PRB concern.
B7 CHECK FOR CONTINUITY BETWEEN LH AND RH PRB
MOTORS ON THE HALL-EFFECT SENSOR POWER AND
GROUND CIRCUITS
Yes
Disconnect: PRB LH Motor C3185. GO to B8 .
Ignition OFF. No
Measure the resistance between LH PRB motor C3185, harness REPAIR the circuit. CLEAR the
side and RH PRB motor C3186, harness side using the DTCs. REPEAT the self-test.
following chart:
LH PRB Motor Circuit RH PRB Motor

C3185-2 CPR47 (GY/BN) C3186-2
C3185-6 RPR47 (BU/GN) C3186-6

B8 CHECK FOR A SHORT TO VOLTAGE IN THE
HALL-EFFECT SENSOR SIGNAL, DEPLOY OR STOW
CIRCUIT
Yes
Disconnect: PRB Module C3313A. DTCs. REPEAT the self-test.
Ignition ON. No
Measure the voltage between LH PRB motor C3185-3, circuit GO to B9 .
VPR43 (GY/BU), harness side and ground; and between LH
230- LEFT R
PRB motor C3185-5, circuit CPR41 (BU/WH), harness side

and ground; and between LH PRB motor C3185-1, circuit
CPR42 (WH), harness side and ground.

B9 CHECK FOR A SHORT TO GROUND IN THE
CIRCUIT
Yes
Measure the resistance between LH PRB motor C3185-3,
circuit VPR43 (GY/BU) and ground; and between LH PRB No
motor C3185-5, circuit CPR41 (BU/WH) and ground; and REPAIR the circuit. CLEAR the
between LH PRB motor C3185-1, circuit CPR42 (WH) and DTCs. REPEAT the self-test.
ground.

B10 CHECK FOR AN OPEN IN THE HALL-EFFECT SENSOR
SIGNAL, DEPLOY OR STOW CIRCUIT
Yes
Measure the resistances between PRB module C3313A or GO to B11 .
C3313B, harness side and LH PRB motor C3185, harness side
REPAIR the circuit(s). CLEAR
self-test.
LH Motor PRB Module

Connector Circuit Connector
C3185-3 VPR43 C3313B-9
(GY/BU)
C3185-5 CPR41 C3313A-1
(BU/WH)
C3185-1 CPR42 (WH) C3313A-2
231- LEFT R

B11 CHECK FOR A SHORT BETWEEN THE STOW AND
DEPLOY CIRCUITS
Yes
Measure the resistance between LH PRB motor C3185-5, INSTALL a new LH PRB
circuit CPR41 (BU/WH), harness side and LH PRB motor motor. REFER to Power
C3185-1, circuit CPR42 (WH), harness side. Running Board (PRB) Motor in
this section. CLEAR the DTCs.
REPEAT the self-test. If the
concern is still present, GO to
B12 .
No
DTCs. REPEAT the self-test.

B12 CHECK THE PRB MODULE FOR CORRECT
OPERATION
Yes
Connect: PRB LH Motor C3185. INSTALL a new PRB module.
Connect: PRB RH Motor C3186. REFER to Power Running
Visually inspect all PRB module connectors. Board (PRB) Module in this
Check for: section. CLEAR the DTCs.
corrosion. REPEAT the self-test.
pushed-out pins.
Connect all PRB module connectors and make sure they seat No
correctly. The system is operating
self-test.
Pinpoint Test C: The Power Running Board (PRB) Does Not Operate Correctly - Right Running Board
Does Not Deploy/Stow or Reverses Direction
Refer to Wiring Diagrams Cell 109 , Power Liftgate/Power Running Boards for schematic and connector
information.
232- LEFT R
Normal Operation
The Power Running Board (PRB) module receives door ajar and vehicle speed status over the Controller Area
Network (CAN). During RH PRB deployment, the PRB module supplies power to the RH PRB motor
through circuit CPR44 (BN/WH) and ground through circuit CPR45 (VT/GY). The PRB module stows the
RH PRB by supplying power to the RH PRB motor through circuit CPR45 (VT/GY) and ground through
circuit CPR44 (BN/WH). The PRB module provides a regulated 10-volt power supply to the Hall-effect
sensor (internal to the PRB motor) through circuit CPR47 (GY/BN). The Hall-effect ground is provided by
the PRB module through circuit RPR47 (BU/GN). The PRB module monitors the RH PRB Hall-effect signal
through circuit VPR46 (GY/OG). If the PRB module does not receive any signal from the Hall-effect sensor
during operation, the PRB will stop.
DTC B2816 (RH Power Running Board Stow Time Fail) - Right running board takes greater than 4
seconds to stow.
DTC B2817 (RH Power Running Board Deploy Time Fail) - Right running board takes greater than 4
seconds to deploy.

Door ajar switch
PRB module
RH PRB motor
PINPOINT TEST C: THE POWER RUNNING BOARD (PRB) DOES NOT OPERATE CORRECTLY - RIGHT RUNNING
BOARD DOES NOT DEPLOY/STOW OR REVERSES DIRECTION

C1 CHECK THE OPERATION OF THE PRB - AUTOMATIC
MODE
Yes
Set the PRB system to the AUTO (enabled) mode, where the The system is operating as
boards automatically deploy when a door on the same side is designed. REVIEW operation of
opened, and retract when the door is closed.li>Open and close the PRBs system with the
the LH front door. The LH PRB should deploy when the door customer.
is open, and retract when the door is closed.
Open and close the LH rear door. The LH PRB should deploy No
when the door is open, and retract when the door is closed. GO to C2 .
Open and close the RH rear door. The RH PRB should deploy
Did both PRBs operate correctly, with no reversal of
motion or noise while in motion?
C2 CHECK THE OPERATION OF THE PRBs - MANUAL
MODE
Yes
Set the PRB system to the OUT mode, where the boards are GO to C6 .
deployed all the time, regardless of door open/closed status and
vehicle speed is less than 8 km/h (5 mph). No
Did both PRB deploy? GO to C3 .
C3 CHECK THE PRB FOR FOREIGN MATERIAL

NOTE: If the system has false bounce back, stops in Yes

mid-travel, is noisy or will not stow completely, extend the The system is operating
PRB and check to see if any foreign material is caught in the normally. The concern may
PRB hinge points, step area or door sill. If foreign material is have been caused by foreign
found, clean the PRB hinge points, step area and door sill with material or blockage in the PRB
a high-pressure washer. If the system operates correctly after hinge points, step area or door
cleaning, refer the customer to the Owner's Literature for sill. REFER the customer to the
correct cleaning instructions. Owner's Literature for correct
Check the PRB hinge points, step area and door sill of the RH cleaning instructions.
PRB for foreign material or blockage. If any foreign material
or blockage is found, remove it, and if necessary, set the PRB No
system to the OUT mode and clean the PRB hinge points, step GO to C4 .
area and door sill with a high-pressure washer. Avoid direct
spray to the motor.
Set the PRB system to the AUTO (enabled) mode, where the
Does the RH PRB operate normally during all test steps?
C4 CHECK REAR PRB BRACKET FOR BINDING (REGULAR
WAGON ONLY)
Yes
Regular wagon only, remove the PRB step. Refer to Power INSTALL a new rear PRB
Running Board (PRB) Step in this section. bracket. REFER to Power
Manually operate the rear PRB bracket by hand. Running Board (PRB) Bracket
Does the rear PRB bracket bind? in this section. TEST system for
normal operation.
No
GO to C5 .
C5 CHECK IF DTCs ARE PRESENT
Yes
Use the recorded PRB module DTCs from the continuous and INSTALL a new PRB motor.
on-demand self tests. REFER to Power Running
Is DTC B2816 or B2817 present? Board (PRB) Motor in this
No
GO to C7 .
C6 VERIFY THE DOOR AJAR SWITCH OPERATION
Yes
Open and close the RH front and RH rear door, and verify the GO to C7 .
interior lights operate correctly and door ajar is noted on the
vehicle message center. No
Do the interior lights turn ON when the door is opened, REFER to Section 417-02 to
and OFF when the door is closed? diagnose the interior lighting
concern before attempting to
diagnose the PRB concern.
C7 CHECK FOR CONTINUITY BETWEEN LH AND RH PRB
GROUND CIRCUITS
PINPOINT TEST C: THE POWER RUNNING BOARD (PRB) DOES NOT OPERATE CORRECTLY
234- RIGHT
Disconnect: PRB LH Motor C3185. Yes

Disconnect: PRB RH Motor C3186. GO to C8 .
Ignition OFF.
Measure the resistance between LH PRB motor C3185, harness No
side and RH PRB motor C3186, harness side using the REPAIR the circuit. CLEAR the
following chart: DTCs. REPEAT the self-test.

C3185-2 CPR47 (GY/BN) C3186-2
C3185-6 RPR47 (BU/GN) C3186-6

C8 CHECK FOR A SHORT TO VOLTAGE IN THE
CIRCUIT
Yes
Disconnect: PRB Module C3313A. DTCs. REPEAT the self-test.
Ignition ON. No
Measure the voltage between RH PRB motor C3186-3, circuit GO to C9 .
VPR46 (GY/OG), harness side and ground; and between RH
PRB motor C3186-5, circuit CPR44 (BN/WH), harness side
and ground; and between RH PRB motor C3186-1, circuit
CPR45 (VT/GY), harness side and ground.

C9 CHECK FOR A SHORT TO GROUND IN THE
CIRCUIT
235- RIGHT
Ignition OFF. Yes

Measure the resistance between RH PRB motor C3186-3, GO to C10 .
circuit VPR46 (GY/OG), harness side and ground; and
between RH PRB motor C3186-5, circuit CPR44 (BN/WH), No
harness side and ground; and between RH PRB motor REPAIR the circuit. CLEAR the
C3186-1, circuit CPR45 (VT/GY), harness side and ground. DTCs. REPEAT the self-test.

C10 CHECK FOR AN OPEN IN THE HALL-EFFECT SENSOR
Yes
Measure the resistances between PRB module C3313A or GO to C11 .
C3313B, harness side and RH PRB motor C3185, harness side
self-test.
RH Motor PRB Module

C3186-3 VPR46 C3313B-10
(GY/OG)
C3186-5 CPR44 C3313A-4
(BN/WH)
C3186-1 CPR45 C3313A-3
(VT/GY)

C11 CHECK FOR A SHORT BETWEEN THE STOW AND
DEPLOY CIRCUITS
236- RIGHT
Measure the resistance between RH PRB motor C3186-5, Yes

circuit CPR44 (BN/WH), harness side and RH PRB motor INSTALL a new RH PRB
C3186-1, circuit CPR45 (VT/GY), harness side. motor. REFER to Power
Running Board (PRB) Motor in
this section. CLEAR the DTCs.
REPEAT the self-test. If the
concern is still present, GO to
C12 .
No
C12 CHECK THE PRB MODULE FOR CORRECT
OPERATION
Yes
Visually inspect all PRB module connectors. Board (PRB) Module in this
pushed-out pins.
Connect all PRB module connectors and make sure they seat No
self-test.
Pinpoint Test D: DTCs B1167, B1168, B1175, B1178, B116B, B116D, B116C and B116E
information.
Normal Operation
During Power Running Board (PRB) deployment, the PRB module supplies power to the PRB motor through
circuit CPR41 (BU/WH) (LH) or CPR44 (BN/WH) (RH) and ground through circuit CPR42 (WH) (LH) or
CPR45 (VT/GY) (RH). The PRB module stows the PRB by supplying power to the PRB motor through
circuit CPR42 (WH) (LH) or CPR45 (VT/GY) (RH) and ground through circuit CPR41 (BU/WH) (LH) or
CPR44 (BN/WH) (RH). The PRB module provides a regulated 10-volt power supply to the Hall-effect sensor
(internal to the PRB motor) through circuit CPR47 (GY/BN). The Hall-effect ground is provided by the PRB
module through circuit RPR47 (BU/GN). The PRB module monitors the PRB Hall-effect signal through
circuit VPR43 (GY/BU) (LH) or VPR46 (GY/OG) (RH). If the PRB module does not receive any signal from
the Hall-effect sensor during operation, the PRB will stop.

B1167 - Left Power Running The PRB module sets this DTC if a short to battery voltage is
Board Deploy and/or Stow Circuit detected in the LH running board motor circuit(s).
Short To Battery
The PRB module sets this DTC if a short to ground is detected in
B1168 - Left Power Running the motor circuit while attempting to retract/stow the LH running
Board Stow Circuit Short To board.
Ground
The PRB module sets this DTC iort to ground is detected in the
B1175 - Right Power Running motor circuit while attempting to retract/stow the RH running
Board Stow Circuit Short To board.
Ground
The PRB module sets this DTC if a short to battery voltage is
B1178 - Right Power Running detected in the RH running board motor circuit(s).
Board Deploy and/or Stow Circuit
Short To Battery
The PRB module sets this DTC if it detects the LH running board
B116B - LH Power Running motor circuit(s) are shorted together.
Board Motor Short
The PRB module sets this DTC if it detects the RH running board
B116C - RH Power Running motor circuit(s) are shorted together.
Board Motor Short
The PRB module sets this DTC when it detects an open in the LH
B116D - LH Power Running running board motor circuit(s).
Board Motor Line Open
The PRB module sets this DTC when it detects an open in the RH
B116E - RH Power Running running board motor circuit(s).
Board Motor Line Open

LH or RH PRB motor assembly
PRB module
PINPOINT TEST D: DTCs B1167, B1168, B1175, B1178, B116B, B116D, B116C AND B116E

D1 CHECK FOR A SHORT TO VOLTAGE IN THE
CIRCUIT
Yes
Ignition OFF. REPAIR the circuit. CLEAR
Disconnect: PRB Module C3313A. the DTCs. REPEAT the
Disconnect: PRB Module C3313B. self-test.
Ignition ON.
For DTC B1167, B1168, B116B or B116D, measure the voltage No
between LH PRB motor C3185-3, circuit VPR43 (GY/BU), GO to D2 .
harness side and ground; and between LH PRB motor C3185-5,
circuit CPR41 (BU/WH), harness side and ground; and between
LH PRB motor C3185-1, circuit CPR42 (WH), harness side and
PINPOINT TEST D: DTCs B1167, B1168, B1175, B1178, B116B, B116D, B116C AND B116E 238
ground.
For DTC B1175, B1178, B116C or B116E, measure the voltage

between RH PRB motor C3186-3, circuit VPR46 (GY/OG),
harness side and ground; and between RH PRB motor C3186-5,
circuit CPR44 (BN/WH), harness side and ground; and between
RH PRB motor C3186-1, circuit CPR45 (VT/GY), harness side
and ground.
D2 CHECK FOR A SHORT TO GROUND IN THE
CIRCUIT
Yes
For DTC B1167, B1168, B116B or B116D, measure the
resistance between LH PRB motor C3185-3, circuit VPR43 No
(GY/BU), harness side and ground; and between LH PRB motor REPAIR the circuit. CLEAR
C3185-5, circuit CPR41 (BU/WH), harness side and ground; and the DTCs. REPEAT the
between LH PRB motor C3185-1, circuit CPR42 (WH), harness self-test.
side and ground.
For DTC B1175, B1178, B116C or B116E, measure the
resistance between RH PRB motor C3186-3, circuit VPR46
(GY/OG), harness side and ground; and between RH PRB motor
C3186-5, circuit CPR44 (BN/WH), harness side and ground; and
between RH PRB motor C3186-1, circuit CPR45 (VT/GY),
harness side and ground.

D3 CHECK FOR AN OPEN IN THE HALL-EFFECT SENSOR
Yes
For DTC B1167, B1168, B116B or B116D, measure the
resistances between PRB module C4322A or C4322B, harness No
side and LH PRB motor C3185-5, harness side using the REPAIR the circuit(s).
following chart: CLEAR the DTCs. REPEAT
the self-test.
LH Motor PRB Module

C3185-3 VPR43 C3313B-9
(GY/BU)
C3185-5 CPR41 C3313A-1
(BU/WH)
C3185-1 CPR42 (WH) C3313A-2
For DTC B1175, B1178, B116C or B116E, measure the

resistances between PRB module C4322A or C4322B, harness
side and RH PRB motor C3186, harness side using the following
chart:
RH Motor PRB Module

C3186-3 VPR46 C3313B-10
(GY/OG)
C3186-5 CPR44 C3313A-4
(BN/WH)
C3186-1 CPR45 (VT/GY) C3313A-3

D4 CHECK FOR A SHORT BETWEEN THE STOW AND
DEPLOY CIRCUITS
For DTC B1167, B1168, B116B or B116D, measure the Yes

resistance between LH PRB motor C3185-5, circuit CPR41 GO to D5 .
(BU/WH), harness side and LH PRB motor C3185-1, circuit
CPR42 (WH), harness side. No
For DTC B1175, B1178 or B116C or B116E, measure the REPAIR the circuit. CLEAR
resistance between RH PRB C3186-5, circuit CPR44 (BN/WH), the DTCs. REPEAT the
harness side and RH PRB motor C3186-1, circuit CPR45 self-test.
(VT/GY), harness side.

D5 CHECK THE PRB MOTOR FOR AN OPEN CIRCUIT
Yes
For DTC B1167, B1168, B116B or B116D, measure the GO to D6 .
resistance between LH PRB motor C3185-5, circuit CPR41
(BU/WH), component side and LH PRB motor C3185-1, circuit No
CPR42 (WH), component side. INSTALL a new PRB motor.
For DTC B1175, B1178, B116C or B116E, measure the REFER to Power Running
resistance between RH PRB motor C3186-5, circuit CPR44 Board (PRB) Motor in this
(BN/WH), component side and RH PRB motor C3186-1, circuit section. CLEAR the DTCs.
CPR45 (VT/GY), component side. REPEAT the self-test.
Is any measurable continuity present?

D6 CHECK THE PRB MOTOR FOR A SHORT TO GROUND
Yes
For DTC B1167, B1168, B116B or B116D, measure the GO to D7 .
resistance between LH PRB motor C3185-1, circuit CPR42
(WH), component side and ground. No
For DTC B1175, B1178, B116C or B116E, measure the INSTALL a new PRB motor.
resistance between RH motor C3186-1, circuit CPR45 (VT/GY), REFER to Power Running
component side and ground. Board (PRB) Motor in this

D7 CHECK THE PRB MODULE FOR CORRECT OPERATION
Yes
Connect: PRB LH Motor C3185. INSTALL a new PRB
Connect: PRB RH Motor C3186. module. REFER to Power
Visually inspect all PRB module connectors. Running Board (PRB)
Check for: Module in this section.
corrosion. CLEAR the DTCs. REPEAT
pushed-out pins. the self-test.
Connect all PRB module connectors and make sure they seat
correctly. No
Is the concern still present? correctly at this time. Concern
may have been caused by a
the self-test.
Pinpoint Test E: DTCs B1162, B1163, B1164 and B1170
information.
Normal Operation
The Power Running Board (PRB) module provides a regulated 10-volt power supply to the Hall-effect sensor
(internal to the PRB motor) through circuit CPR47 (GY/BN). The Hall-effect ground is provided by the PRB
module through circuit RPR47 (BU/GN). The PRB module monitors the PRB Hall-effect signal through
circuit VPR43 (GY/BU) (LH) or VPR46 (GY/OG) (RH). If the PRB module does not receive any signal from
the Hall-effect sensor during operation, the PRB will stop.

The PRB module sets this DTC if it detects the Hall-effect sensor
B1162 - Power Running Board power circuit is shorted to battery voltage.
Hall Effect Sensor Power
Circuit Short To Battery
The module sets this DTC if it does not see any feedback from the
B1163 - Left Power Running Hall-effect sensor during the stowing/deploying of the LH running
Board Hall Effect Sensor board.
Failure
The PRB module sets this DTC if it detects the Hall-effect sensor
B1164 - Power Running Board power circuit is shorted to ground.

Hall Effect Sensor Power

Circuit Short To Ground
The PRB module sets this DTC if it does not see any feedback from
B1170 - Right Power Running the Hall-effect sensor during the stowing/deploying of the RH
Board Hall Effect Sensor running board.
Failure

PRB module
LH or RH PRB motor assembly
PINPOINT TEST E: DTCs B1162, B1163, B1164 AND B1170

E1 CHECK CONTINUITY BETWEEN LH AND RH PRB
GROUND CIRCUITS
Yes
Disconnect: PRB LH Motor C3185. GO to E2 .
Ignition OFF. No
Measure the resistance between LH PRB motor C3185, harness REPAIR the circuit. CLEAR the
side and RH PRB motor C3186, harness side using the DTCs. REPEAT the self-test.
following chart:

C3185-2 CPR47 (GY/BN) C3186-2
C3185-6 RPR47 (BU/GN) C3186-6

E2 CHECK THE HALL-EFFECT SENSOR POWER AND
GROUND
PINPOINT TEST E: DTCs B1162, B1163, B1164 AND B1170 243

Ignition ON. Yes

Measure the voltage between RH PRB motor C3186-2, circuit GO to E7 .
CPR47 (GY/BN), harness side and RH PRB motor C3186-6,
circuit RPR47 (BU/GN), harness side. No
If the voltage was less than 7
volts, GO to E3 . If the voltage
was greater than 10.5 volts, GO
to E6 .
Open the RH door.

E3 CHECK THE HALL-EFFECT SENSOR POWER CIRCUIT
FOR VOLTAGE
Yes
Measure the voltage between RH PRB motor C3186-2, circuit GO to E5 .
CPR47 (GY/BN), harness side and ground.
No
GO to E4 .
Open the RH door.

E4 CHECK HALL-EFFECT SENSOR POWER CIRCUIT FOR
AN OPEN OR SHORT TO GROUND
Yes
Measure the resistance between RH PRB motor C3186-2, No
circuit CPR47 (GY/BN), harness side and PRB module REPAIR the circuit. CLEAR the
C3313B-5, circuit CPR47 (GY/BN), harness side; and between DTCs. REPEAT the self-test.
RH PRB motor C3186-2, circuit CPR47 (GY/BN), harness side
and ground.

Is the resistance less than 5 ohms between the PRB motor

and the PRB module; and greater than 10,000 ohms
between the PRB motor and ground?
E5 CHECK THE HALL-EFFECT SENSOR GROUND
CIRCUIT FOR AN OPEN
Yes
Measure the resistance between RH PRB motor C3186-6, No
circuit RPR47 (BU/GN), harness side and PRB module REPAIR the circuit. CLEAR the
C3313B-14, circuit RPR47 (BU/GN), harness side. DTCs. REPEAT the self-test.

E6 CHECK THE HALL-EFFECT SENSOR POWER CIRCUIT
FOR A SHORT TO VOLTAGE
Yes
Disconnect: PRB Module C3313B. DTCs. REPEAT the self-test.
Ignition ON.
Measure the voltage between RH PRB motor C3186-2, circuit No
CPR47 (GY/BN), harness side and ground. GO to E9 .

E7 CHECK THE HALL-EFFECT SENSOR SIGNAL CIRCUIT
Yes
Disconnect: PRB Module C3313B. DTCs. REPEAT the self-test.
Ignition ON.
For DTC B1163, measure the voltage between LH PRB motor No
C3185-3, circuit VPR43 (GY/BU), harness side and ground. GO to E8 .
For DTC B1170, measure the voltage between RH PRB motor
C3186-3, circuit VPR46 (GY/OG), harness side and ground.


E8 CHECK THE HALL-EFFECT SENSOR SIGNAL CIRCUIT
FOR AN OPEN OR SHORT TO GROUND
Yes
For DTC B1163, measure the resistance between LH PRB
motor C3185-3, circuit VPR43 (GY/BU), harness side and No
PRB module C3313B-9, circuit VPR43 (GY/BU), harness side; REPAIR the circuit. CLEAR the
and between LH PRB motor C3185-3, circuit VPR43 DTCs. REPEAT the self-test.
(GY/BU), harness side and ground.
For DTC B1170, measure the resistance between RH PRB

motor C3186-3, circuit VPR46 (GY/OG), harness side and
PRB module C3313B-10, circuit VPR46 (GY/OG), harness
side; and between RH PRB motor C3186-3, circuit VPR46
(GY/OG), harness side and ground.
Is the resistance less than 5 ohms between the PRB motor

and PRB module; and greater than 10,000 ohms between
the PRB motor and ground?
E9 CHECK THE PRB MODULE FOR CORRECT
OPERATION
Yes
Disconnect all PRB module connectors. Board (PRB) Module in this
pushed-out pins.
No

Connect all PRB module connectors and make sure they seat The system is operating
correctly. correctly at this time. Concern
Operate the system and verify the concern is still present. may have been caused by a
Is the concern still present? loose or corroded connector.
the self-test.
E10 CHECK THE PRB MODULE FOR CORRECT
OPERATION
Yes
Connect: PRB LH Motor C3185. GO to E11 .
Connect: PRB RH Motor C3186.
Disconnect all PRB module connectors. No
Check for: The system is operating
corrosion. correctly at this time. Concern
pushed-out pins. may have been caused by a
Connect all PRB module connectors and make sure they seat loose or corroded connector.
correctly. CLEAR the DTCs. REPEAT
Operate the system and verify the concern is still present. the self-test.
E11 CHECK THE PRB FOR FOREIGN MATERIAL
Yes
NOTE: If the system has false bounce back, stops in The system is operating
mid-travel, is noisy or will not deploy or stow completely, normally. The concern may
extend the PRB and check to see if any foreign material is have been caused by foreign
caught in the PRB hinge points, step area or door sill. If foreign material or blockage in the pivot
material is found, clean the PRB hinge points, step area and areas or track guides. REFER
door sill with a high-pressure washer. If the system operates the customer to the Owner's
correctly after cleaning, refer the customer to the Owner's Literature for correct cleaning
Literature for correct cleaning instructions. instructions.
Check the PRB hinge points, step area and door sill of the PRB
s for foreign material or blockage. If any foreign material or No
blockage is found, remove it, and if necessary, set the PRB INSTALL a new PRB motor.
system to the OUT mode and clean the PRB hinge points, step REFER to Power Running
area and door sill with a high-pressure washer. Avoid direct Board (PRB) Motor in this
spray to the motor. section. CLEAR the DTCs.
Set the PRB system to the AUTO (enabled) mode, where the REPEAT the self-test.
Open and close the LH front door. The LH PRB should deploy
Do the LH and RH PRBs operate normally during all test
steps?
Pinpoint Test F: DTC B1317/B1318 - Battery Voltage High/Battery Voltage Low
information.
NOTE: DTC B1317 or B1318 can be set if the vehicle has been recently jump started, the battery has been
recently charged or the battery has been discharged. The battery may become discharged due to excessive

load(s) on the charging system from aftermarket accessories or if the battery habeen left unattended with the
accessories on.
Normal Operation
The Power Running Board (PRB) module continuously monitors the input voltage for correct operation. If the
PRB module detects input voltage below 9.5 volts, it will store DTC B1318 in memory. If the PRB module
detects input voltage greater than 16 volts, it will store DTC B1317 in memory. If the PRB module sets DTC
B1317 or B1318, it will inhibit the power liftgate system operation.
DTC B1317 (Battery Voltage High) - If the PRB module detects voltage above 16 volts while the
running boards are in motion (deploy/stow), it will set this DTC. Once this DTC is set, the PRB
system will be disabled until the battery voltage returns to normal.
DTC B1318 (Battery Voltage Low) - If the PRB module detects voltage below 9.5 volts while the
running boards are in motion (deploy/stow), it will set this DTC.

PRB module
PINPOINT TEST F: DTC B1317/B1318 - BATTERY VOLTAGE HIGH/BATTERY VOLTAGE LOW

F1 RETRIEVE ALL CMDTCs IN ALL MODULES
Yes
Ignition ON. REFER to Section 414-00 to diagnose
Enter the following diagnostic mode on the scan tool: the charging system. CLEAR all
Self Test - ALL CMDTCs . Continuous Memory Diagnostic
Is DTC B1317 or B1318 retrieved from one or more Trouble Codes (CMDTCs). REPEAT
modules and P0563, P0620, P0626 or P065B retrieved the PRB module self-test.
from the PCM?
No
GO to F2 .
F2 TEST BATTERY CONDITION
Yes
Ignition OFF. If the battery passed the condition test
Carry out the Battery Condition Test. Refer to Section but required a recharge, REFER to
414-01 . Section 414-00 to diagnose the
Did the battery pass the condition test? charging system. CLEAR all
CMDTCs . REPEAT the PRB module
self-test.
If the battery passed the condition test

and did not require a recharge, GO to
F3 .
No
INSTALL a new battery. CLEAR all
CMDTCs . REPEAT the PRB module

self-test.
F3 CHECK CHARGING SYSTEM VOLTAGE
Yes
NOTE: Do not allow the engine speed to increase above For DTC B1318, GO to F4 .
2,000 rpm while performing this step or the generator
may self excite and result in default charging system For DTC B1317, GO to F6 .
output voltage. If engine speed goes above 2,000 rpm,
shut the vehicle OFF and restart the engine before No
performing this step. REFER to Section 414-00 to diagnose
the charging system. CLEAR all
Measure the voltage of the battery: CMDTCs . REPEAT the PRB module
For DTC B1317, turn off all accessories and run self-test.
the engine at 1,500 rpm for a minimum of 2
minutes while measuring battery voltage.
For DTC B1318, turn on headlights and HVAC
fan on high and run engine at 1,500 rpm for a
minimum of 2 minutes while measuring battery
voltage.

F4 CHECK THE PRB MODULE POWER CIRCUIT
Yes
Ignition OFF. GO to F5 .
Measure the voltage between PRB module C3313B-1, No
circuit SBB11 (BU/RD), harness side and ground. VERIFY Battery Junction Box (BJB)
fuse 11 (40A) is OK. If OK, REPAIR
the circuit. CLEAR the DTCs.
REPEAT the PRB module self-test. If
not OK, REFER to the Wiring
Diagrams manual to identify the
possible causes of the circuit short.
CLEAR the DTCs. REPEAT the PRB
module self-test.

F5 CHECK THE PRB MODULE GROUND CIRCUIT
FOR AN OPEN
Yes
Measure the resistance between PRB module C3313B-4, GO to F6 .
circuit GD143 (BK/VT), harness side and ground.
No
DTCs. REPEAT the PRB module
self-test.

249

F6 CHECK FOR PRB MODULE OPERATION
Yes
Check PRB module C3313A and C3313B for the INSTALL a new PRB module.
following: REFER to Power Running Board
corrosion. (PRB) Module in this section.
damaged pins. REPEAT the PRB module self-test.
pushed-out pins.
Connect PRB module C3313A and C3313B and make No
sure the connectors seat correctly. The system is operating correctly at
Clear all CMDTCs . this time. The concern may have been
Operate the system to verify the concern is still present. caused by a loose or corroded
Is the concern still present? connector. CLEAR the DTCs.
REPEAT the PRB module self-test.

250
Radiator Grille
Expedition

1 17D957 Front bumper cover assembly
2 N800488 Bumper assembly-to-grille nuts (4 required)
3 1542528 Emblem
4 8200 Radiator grille assembly
5 16758 Bumper assembly-to-grille bracket
6 - Rivets (4 required)
7 - Radiator grille upper air deflector
Navigator

1 17D957 Front bumper cover assembly
2 8200 Radiator grille assembly
Radiator Grille 251

3 - Rivets (4 required)
4 - Radiator grille upper air deflector
5 17D635 Lower radiator grille assembly
All vehicles
Expedition only
2. Remove the 4 bumper assembly-to-grille bracket retainer nuts and the bumper assembly-to-grille
bracket.
All vehicles
3. NOTE: Expedition shown, Navigator similar.
Remove the clips and remove the front grille.
Navigator 252
Navigator 253
Power Running Board (PRB)
Regular Wagon
NOTE: LH shown, RH similar.

1 W701834 Power Running Board (PRB) retaining upper
bolts (4 required per side)
2 W701834 PRB retaining lower bolts (4 required per side)
3 16451A LH/ PRB assembly
16450A RH
Extended Wagon

1 W701834 Power Running Board (PRB) retaining upper
bolts (4 required per side)

3 16451B LH/ PRB assembly

16450B RH
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .
2. NOTE: If the Power Running Board (PRB) cannot be extracted, extend the running board by hand.
Extend the PRB .
3. Disconnect the PRB motor electrical connector.
4. NOTICE: An assistant is required to hold the Power Running Board (PRB) before removing the
lower bolts. Failure to follow this instruction may result in damage to the component.
NOTE: Only 3 bolts shown.
Remove the front PRB upper and lower bolts.
5. Remove the rear PRB upper and lower bolts and remove the PRB assembly.
Extended Wagon 255

Extended Wagon 256

Power Running Board (PRB) Motor
1. The Power Running Board (PRB) motor is serviced by installing a new PRB front bracket assembly
for the regular wagon and a new bracket assembly for the extended wagon. For additional
information, refer to Power Running Board (PRB) Bracket in this section.
Power Running Board (PRB) Motor 257

Power Running Board (PRB) Bracket
Regular Wagon

1 - Power Running Board (PRB) step screws (4
required per side)
2 16490A PRB step assembly
3 W701834 PRB retaining lower bolts (4 required per
side)
4 W701834 PRB retaining upper bolts (4 required per
side)
5 16A506A RH/ PRB bracket assembly - front
16A507A LH
6 16A506D RH/ PRB bracket assembly - rear
16A507C LH
Extended Wagon
Power Running Board (PRB) Bracket 258


1 - Power Running Board (PRB) step screws (part
of 16490B) (4 required per side)
2 16490B PRB step assembly
4 W701834 PRB retaining upper bolts (4 required per side)
5 16A507B LH/ PRB bracket assembly
16A506B RH
All brackets
1. Remove the Power Running Board (PRB) step. For additional information, refer to Power Running
Board (PRB) Step in this section.
Front bracket - regular wagon
2. NOTE: The PRB motor is part of the front bracket assembly.
Disconnect the PRB motor electrical connector.
3. NOTE: Only 3 bolts shown.
Remove the PRB front bracket 2 upper and 2 lower bolts and the front bracket assembly.
Extended Wagon 259

Rear bracket - regular wagon
4. Remove the PRB rear bracket 2 upper and 2 lower bolts and the rear bracket assembly.
Extended wagon
5. NOTICE: An assistant is required to hold the Power Running Board (PRB) bracket assembly
prior to removing the bolts. Failure to follow this instruction may result in damage to the
component.
Remove the 4 frontnd rear bracket upper and lower bolts.
All brackets
Extended Wagon 260

Extended Wagon 261

Power Running Board (PRB) Module
Part
1 - Electrical connectors
2 W506404 Power Running Board (PRB) module retaining bolts (2
required)
3 14C177 PRB module assembly
4 W520821 U-nuts (2 required)
1. Remove the LH B-pillar trim panel. For additional information, refer to Section 501-05 .
2. Disconnect the Power Running Board (PRB) module electrical connectors.
3. Remove the 2 bolts and the PRB module assembly.
Power Running Board (PRB) Module 262

Power Running Board (PRB) Module 263

Power Running Board (PRB) Step
Regular Wagon
Part
1 - Power Running Board (PRB) step screws (4 required
per side)
2 16490A PRB step assembly
Extended Wagon
Part
1 - Power Running Board (PRB) step screws (4 required
per side)
2 16490B PRB step assembly
Power Running Board (PRB) Step 264

1. Extend the Power Running Board (PRB).
2. NOTICE: An assistant is required to hold the Power Running Board (PRB) before removing the
bracket-to-step screws. Failure to follow this direction may result in damage to the component.
Remove the 2 front and 2 rear bracket-to-step screws and the PRB step.
Extended Wagon 265

Fuel Filler Door Cup Bezel

1 9A212 Fuel filler door cup bezel
Removal
NOTICE: The fuel filler door cup bezel is a one-time use only part. Removal of this part will result in
damage to the component.
NOTICE: Do not attempt to pry on the bottom of the fuel filler door cup bezel. Failure to follow this
direction may result in damage to the vehicle.
1. Using a non-marring body tool, pry outward on the upper RH side of the fuel filler door cup bezel
until the clip breaks.
2. Using a non-marring body tool, pry the upper LH side of the fuel filler door cup bezel until the clip
breaks.
3. Pull upward and outward to remove the fuel filler door cup bezel.
Installation
Fuel Filler Door Cup Bezel 266

1. NOTICE: Make sure to align the fuel filler door cup bezel to the alignment slots and the filler
neck. Failure to follow this direction may result in damage to the component and/or vehicle.
Align the fuel filler door cup bezel to the vehicle.
2. Push inward and downward until the clips snap into place.

SECTION 501-09: Rear View Mirrors 2011 Expedition, Navigator Workshop Manual
Description Nm lb-in
Exterior mirror nuts 9 80

Rear View Mirrors
Exterior Mirrors
The main components of the exterior rear view mirrors are:
LH exterior auto-dimming mirror glass

Exterior mirror control switch
Exterior mirror glass
Exterior mirror glass adjustment motors
Exterior mirror cover (optional - chrome or painted)
Exterior mirror head power folding motor (optional and not replaceable - power folding mirrors only)
Driver Seat Module (DSM) (optional - memory exterior mirrors)
Turn signal module
Puddle lamp
For information on the puddle lamps, refer to Section 417-01 .
Heated Exterior Mirrors
The power exterior rear view mirrors are available with a heated mirror glass feature, which heats the mirror
glass to remove frost, snow, ice and condensation. The rear window defrost switch controls the operation of
the heated exterior rear view mirrors. The heated exterior rear view mirrors only operate when the rear
window defrost system is in the ON position.
Power Folding Mirrors
The power folding mirror option allows both power exterior rear view mirrors to be folded or unfolded. Power
folding mirrors can be identified by the words FOLD/UNFOLD on the exterior mirror control switch. When
the exterior mirror control switch is set to the center position and pressed rearward to the FOLD/UNFOLD
position, the LH and RH exterior mirrors will fold in towards the door if they are folded out, or unfold
outwards if they are folded in. The RH and LH power folding mirrors will fold and unfold at the same time
and cannot be controlled independently. If the power folding mirrors are folded or unfolded continuously for 6
to 10 cycles, the power lockout feature will disable the system for approximately 7-10 minutes to prevent
damage to the power fold motors. After 7-10 minutes have elapsed, normal operation will resume.
The power folding mirrors must be synchronized any time the mirrors are folded orded without using the
mirror control switch, or if a new power folding mirror has been installed. Refer to Exterior Mirror Motor
Synchronization - Power Folding in this section.
Memory Exterior Mirrors
The memory exterior mirror function recalls the preferred positioning of the LH and RH exterior mirror glass
that is retained in the DSM memory. The DSM monitors the exterior mirror control switch and controls the
movement of the RH and LH exterior mirror motors. The memory exterior mirror function is activated by the
door mounted switches or the Remote Keyless Entry (RKE) transmitter. When a memory position is recalled
by the operator, the LH and RH exterior mirror glass will automatically adjust to the preferred position. The
DSM is capable of setting a DTC for the memory mirror system when a system concern exists.
For information on the DSM and memory position programming, refer to Section 501-10 .
Rear View Mirrors 269

Exterior Mirror with Integrated Blind Spot Mirror
The exterior mirrors may be equipped with exterior mirror glass that has an integrated blind spot mirror. The
integrated blind spot mirror is located in the upper outboard corner of the exterior mirror glass.
Interior Mirror
Interior Rear View Mirrors
The vehicle may be equipped with one of the following interior rear view mirrors:
Interior auto-dimming rear view mirror with compass

Interior auto-dimming rear view mirror with compass and microphone
Interior auto-dimming rear view mirror with compass, microphone and video display
Interior Auto-Dimming Rear View Mirror
The LH exterior and interior rear view auto-dimming mirrors adjusts the reflectance level of the mirror glass
to eliminate unwanted glare. The reflectance level of the mirror glass is variable and depends on the amount
of rear glare in relation to ambient light conditions in front of the interior mirror. To provide increased
visibility when backing up, the LH exterior and interior rear view mirrors automatically return to a high
reflectance mode whenever the gear selector is in REVERSE.
On vehicles equipped with a compass, the interior rear view mirror will be equipped with an integrated
compass module. For compass information, calibration or diagnostics, refer to Section 413-01 .
On vehicles equipped with SYNC, the interior rear view mirro will be equipped with an integrated
microphone. For microphone information or diagnostics, refer to Section 415-00 .
On vehicles equipped with a rear-mounted object detection camera, a video image will be displayed on the LH
side of the interior rear view mirror glass when the gear selector is in REVERSE. For information on the
rear-mounted object detection system, refer to Section 413-13 .
Memory Exterior Mirrors 270

Interior Auto-Dimming Rear View Mirror 271

Rear View Mirrors - Exterior
Special Tool(s)
Flex Probe Kit

NUD105-R025DE or equivalent


The movement of the LH and RH exterior mirror glass is controlled by the exterior mirror control switch and
the LH and RH exterior mirror motors. Adjusting the exterior mirror switch to the LH or RH position
determines which exterior mirror motor will be controlled.
If equipped with power folding mirrors, the center position of the exterior mirror control switch controls the
powerding mirrors.
The exterior mirrors use a jumper harness between the vehicle wire harness connector and the exterior mirror
motor. The exterior mirror jumper harness is integral to the exterior mirror. Before replacing an exterior
mirror or mirror motor, inspect the jumper harness for open and shorted circuits or damaged and pushed-out
pins. If a concern with the exterior mirror jumper harness exists, an attempt to repair the jumper harness
should be made.
Only vehicles equipped with memory exterior mirrors are capable of setting DTCs.
Heated Exterior Mirrors
The rear window defrost switch controls the operation of the heated exterior mirrors. The heated exterior
mirrors only operate when the rear window defrost is ON. The heated exterior mirror power is supplied by the
rear window defrost relay through Battery Junction Box (BJB) fuse 23 (15A), which isolates the heated
exterior mirrors from the rear window defrost system in the event of a concern. The heated mirrors are heated
for a period of 10 minutes when the engine is running and the heated mirror switch is pressed to the ON
position.
Memory Exterior Mirrors
The movement of the LH and RH exterior mirror glass is controlled by the exterior mirror control switch,
Driver Seat Module (DSM) and the LH and RH exterior mirror motors. Adjusting the exterior mirror switch to
the LH or RH position determines which exterior mirror motor will be controlled. The exterior mirror control
switch sends voltage and ground input signals to the DSM . The DSM will provide the appropriate voltage
and ground to the appropriate mirror motor in order to move the mirror motor to the desired position.
Rear View Mirrors - Exterior 272

The memory exterior mirrors feature allows the driver to program personalized mirror positions that can be
recalled using the memory switches or remote transmitter. There are 2 memory settings possible. The power
driver seat positions are also stored and recalled with the memory exterior mirror positions. The memory
mirror function recalls the preferred positioning of the exterior mirrors when the transmission is in the PARK
or NEUTRAL position and the door mounted switches or the Remote Keyless Entry (RKE) transmitter are
activated. The DSM constantly tracks the exterior mirror position by using the potentiometers in the exterior
mirror assembly. The positions remain in memory as long as the DSM retains power. When a memory
position is recalled by the operator, the DSM powers the exterior mirror motors simultaneously and monitors
the potentiometer circuits. When the stored memory position is reached, the DSM removes the voltage from
the motors. If the exterior mirror control switch is operated during a memory recall, the DSM stops the recall
and responds to the exterior mirror control switch command. The DSM is capable of setting a DTC for the
memory mirror system when a system concern exists.
For information on the DSM and memory position programming, refer to Section 501-10 .
Power Folding Mirrors
NOTE: The power folding mirrors may need to be synchronized when the RH, LH or both power folding
mirrors are partially folded in toward the door manually, and then folded inward using the power folding
mirror control switch. Refer to Exterior Mirror Motor Synchronization - Power Folding in this section.
NOTE: Before running a self-test diagnostic or retrieving DTCs, the power fold switch must be inactive for at
least 30 seconds. Retrieving DTCs before 30 seconds will result in false DTCs.
The power folding exterior mirrors are controlled by the DSM . The power folding exterior mirror feature
allows both exterior mirrors to be folded or unfolded using the exterior mirror control switch. When the
exterior mirror control switch is set to the center position and pressed rearward to the FOLD/UNFOLD
position, the exterior mirror control switch sends a signal to the DSM which then supplies power and ground
to the exterior mirrors to fold or unfold the mirrors. The RH and LH power folding mirrors will fold or unfold
at the same time and cannot be controlled independently. The power folding mirrors contain a drive motor that
is not replaceable. If a power folding mirror drive motor is found to be inoperative, a new power folding
exterior rear view mirror assembly must be installed. If the power folding mirrors are folded or unfolded
continuously (6 to 10 cycles), the power lockout feature will disable the system for approximately 7-10
minutes to prevent damage to the power folding mirror drive motors. After 7-10 minutes have elapsed, normal
operation will resume. Before running a self-test or retrieving DTCs, the power fold switch must be inactive
for at least 30 seconds.
Turn Signal Mirror
The exterior mirror may be equipped with a mirror-mounted turn signal assembly. For the mirror-mounted
turn signal Description and Operation, service procedures or Diagnosis and Testing, refer to Section 417-01 .
Puddle Lamps
The exterior mirrors may be equipped with puddle lamps, which will illuminate when the interior lights are
turned on by opening a door or by pressing the unlock button on the remote transmitter, if equipped. For the
mirror-mounted puddle lamp Description and Operation, service procedures or Diagnosis and Testing, refer to
Section 417-01 .
1. Verify the customer concern by operating the power exterior mirrors or memory mirrors.

2. Visually inspect for obvious signs of mechanical, impact damage, dirt and electrical damage.
Exterior mirror Smart Junction Box (SJB) fuse 12

Exterior mirror control switch (7.5A)
Exterior mirror cover Battery Junction Box (BJB) fuse 59
Exterior mirror glass (15A)
Exterior mirror glass dampener Driver Seat Module (DSM)
springs Exterior mirror control switch
Exterior mirror motor Exterior mirror motor
Exterior mirror
Loose or corroded connections
Wiring harness
Cut wires
Bent pins
5. NOTE: The Vehicle Communication Module (VCM) LED prove-out confirms power and ground


refer to Section 418-00 to diagnose no response from the DSM .

418-00 .
(CMDTCs).
8. Clear the continuous DTCs and carry out the self-test diagnostics for the DSM .

9. If the DTCs retrieved are related to the concern, go to the Driver Seat Module (DSM) DTC Chart. For
all other DTCs, refer to Section 419-10 .
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart - Exterior Mirrors or GO to
Symptom Chart - NVH .
DTC Charts
Driver Seat Module (DSM) DTC Chart

B112B Mirror Power Fold Switch Input Short to Battery GO to Pinpoint Test E .
B1667 Mirror Driver Up/Down Motor Stalled GO to Pinpoint Test D .
B1668 Mirror Driver Right/Left Motor Stalled GO to Pinpoint Test D .
B1669 Mirror Passenger Up/Down Motor Stalled GO to Pinpoint Test D .
B1670 Mirror Passenger Right/Left Motor Stalled GO to Pinpoint Test D .
B1733 Mirror Driver Vertical Switch Circuit Failure GO to Pinpoint Test D .
B1737 Mirror Driver Horizontal Switch Circuit Failure GO to Pinpoint Test D .
B1741 Mirror Passenger Vertical Switch Circuit Failure GO to Pinpoint Test D .
B1745 Mirror Passenger Horizontal Switch Circuit Failure GO to Pinpoint Test D .
B2223 Mirror Driver Drive Circuit Failure GO to Pinpoint Test D .
B2224 Mirror Passenger Drive Circuit Failure GO to Pinpoint Test D .
B2312 Mirror Passenger Horizontal Feedback Potentiometer Circuit GO to Pinpoint Test D .
Failure
B2314 Mirror Passenger Horizontal Feedback Potentiometer Circuit Short GO to Pinpoint Test D .
to Battery
B2316 Mirror Passenger Vertical Feedback Potentiometer Circuit Failure GO to Pinpoint Test D .
B2318 Mirror Passenger Vertical Feedback Potentiometer Circuit Short to GO to Pinpoint Test D .
Battery
B2320 Mirror Driver Horizontal Feedback Potentiometer Circuit Failure GO to Pinpoint Test D .
B2322 Mirror Driver Horizontal Feedback Potentiometer Circuit Short to GO to Pinpoint Test D .
Battery
B2324 Mirror Driver Vertical Feedback Potentiometer Circuit Failure GO to Pinpoint Test D .
B2326 Mirror Driver Vertical Feedback Potentiometer Circuit Short to GO to Pinpoint Test D .
Battery
All other - REFER to Section
DTCs 501-10 .
Symptom Chart - Exterior Mirrors
Symptom Chart - Exterior Mirrors

The Exterior VERIFY by cleaning the exterior glass. If glass is still

mirror mirror blemished, INSTALL a new exterior mirror glass.
glass is glass REFER to Exterior Mirror Glass in this section.
blemished
Symptom Chart - NVH
Symptom Chart - NVH

possible any one of multiple systems may be the cause of a symptom, it may be necessary to use a process of
elimination type of diagnostic approach to pinpoint the responsible system. If this is not the causal system for
the symptom, refer back to Section 100-04 for the nexkely system and continue diagnosis.
Mirror vibrates/loose
Exterior mirror motor screws loose
REMOVE mirror glass and TIGHTEN the 3 exterior mirror motor screws.
Exterior mirror mounting nuts loose
TIGHTEN the exterior mirror mounting nuts. REFER to the Torque Specifications table.
Mirror glass loose
PRESS the center of the exterior mirror glass up, down, left and right to make sure that the exterior
mirror glass is seated correctly. If the exterior mirror glass is still loose, REMOVE the exterior mirror
glass and INSPECT the exterior mirror backing plate for damage. If the exterior mirror backing plate
is damaged, INSTALL a new exterior mirror glass. REFER to Exterior Mirror Glass in this section.
Aftermarket air deflector/stone shields
If possible, REMOVE aftermarket air deflector/stone shield, then ROAD TEST the vehicle. If
concern is no longer present, ADVISE customer that aftermarket components were causing undesired
vibration.
Power folding mirrors are not synchronized
SYNCHRONIZE the power folding mirrors. REFER to Exterior Mirror Motor Synchronization -
Power Folding in this section.
Exterior mirror is structurally damaged
INSPECT the power folding mirror for structural damage. If necessary, INSTALL a new power
folding mirror. REFER to Exterior Mirror in this section.
Exterior mirror motor cracked
INSTALL a new exterior mirror motor. REFER to Exterior Mirror Motor in this section.

Exterior mirror glass dampener springs missing (LH only) or damaged
INSTALL a new exterior mirror glass. REFER to Exterior Mirror Glass in this section.
Wind noise
Foam gasket between exterior mirror and door is damaged or misaligned
VERIFY gasket is in good condition. If necessary, REPOSITION foam gasket between exterior rear
view mirror and door frame or REPAIR the foam gasket if possible.
Exterior mirror is not correctly fitted to the door
VERIFY that there are no gaps between the exterior mirror and the door. If necessary, LOOSEN the
exterior mirror nuts and REPOSITION the exterior mirror.
Exterior mirror cover
VERIFY that the exterior mirror cover is not loose or broken. If necessary, INSTALL a new exterior
mirror cover. REFER to Exterior Mirror Cover in this section.
Exterior mirror plastic housing damaged/joints knocked out of alignment
SNAP the misaligned pieces into place if possible. If the mirror cannot be aligned, INSTALL a new
exterior mirror. REFER to Exterior Mirror in this section.
Pinpoint Tests
Pinpoint Test A: The Mirrors are Inoperative - Non-Memory Mirrors
Refer to Wiring Diagrams Cell 124 , Power Mirrors for schematic and connector information.
Normal Operation
The exterior mirror control switch receives voltage at all times from the Smart Junction Box (SJB). The
exterior mirror control switch has only one ground circuit. The exterior mirrors share a common circuit for
both up/down and right/left movement.

Fuse
PINPOINT TEST A: THE MIRRORS ARE INOPERATIVE - NON-MEMORY MIRRORS

A1 CHECK FOR VOLTAGE TO THE

EXTERIOR MIRROR CONTROL SWITCH
Yes
Disconnect: Exterior Mirrontrol Switch C527 . GO to A2 .
Measure the voltage between exterior mirror
control switch C527-1, circuit SBP12 (GN/RD), No
harness side and ground. VERIFY that SJB fuse 12 (7.5A) is OK. If OK,
REPAIR the circuit. If not OK, REFER to the
Wiring Diagrams manual to identify the
possible causes of the circuit short. TEST the

A2 CHECK FOR GROUND TO THE EXTERIOR
MIRROR CONTROL SWITCH
Yes
Measure the resistance between exterior mirror GO to A3 .
control switch C527-3, circuit GD143
(BK/VT), harness side and ground. No
REPAIR the circuit. TEST the system for
normal operation.

A3 CHECK THE EXTERIOR REAR VIEW
MIRROR COMMON CIRCUIT FOR A SHORT
TO VOLTAGE
Yes
Disconnect: LH Exterior Mirror C516. REPAIR the circuit. TEST the system for
Disconnect: LH Exterior Mirror C622. normal operation.
Ignition ON.
Measure the voltage between exterior mirror No
control switch C527-6, circuit CPM23 (GY), GO to A4 .
PINPOINT TEST A: THE MIRRORS ARE INOPERATIVE - NON-MEMORY MIRRORS 278


MIRROR COMMON CIRCUIT FOR A SHORT
TO GROUND
Yes
Measure the resistance between exterior mirror
control switch C527-6, circuit CPM23 (GY), No
harness side and ground. REPAIR the circuit. TEST the system for
normal operation.

MIRROR COMMON CIRCUIT FOR AN OPEN
Yes
Measure the resistance between exterior mirror INSTALL a new exterior mirror control switch.
control switch C527-6, circuit CPM23 (GY), REFER to Exterior Mirror Control Switch in
harness side and LH exterior mirror C516-4, this section. TEST the system for normal
circuit CPM23 (GY), harness side. operation.
No
normal operation.
Pinpoint Test B: A Single Mirror is Inoperative - Non-Memory Mirrors
Normal Operation
The exterior mirror control switch uses a common circuit for both exterior mirror down/up and left/right
movement.

Exterior mirror motor
Exterior mirror

PINPOINT TEST B: A SINGLE MIRROR IS INOPERATIVE - NON-MEMORY MIRRORS

B1 CHECK THE EXTERIOR
Yes
Disconnect: Exterior Mirror
Control Switch C527 . No
Carry out the Exterior Mirror INSTALL a new exterior mirror control switch. REFER to
Control Switch component test. Exterior Mirror Control Switch in this section. TEST the
Refer to Wiring Diagramsl 149
for component testing.
Did the exterior mirror control
switch pass the component test?
B2 CHECK THE EXTERIOR REAR
VIEW MIRROR COMMON CIRCUIT
FOR AN OPEN
Yes
Disconnect: RH Exterior Mirror CHECK the inoperative exterior mirror jumper harness
C622 or LH Exterior Mirror between the vehicle harness and the exterior mirror motor for
C516. open circuits and damaged or pushed-out pins. If the jumper
Measure the resistance: harness is not OK, REPAIR the jumper harness. If the jumper
for LH inoperative mirror, harness cannot be repaired, INSTALL a new exterior mirror.
between C516-4, circuit REFER to Exterior Mirror in this section. If the jumper
CPM23 (GY), harness harness is OK, INSTALL a new exterior mirror motor.
side and exterior mirror REFER to Exterior Mirror Motor in this section. TEST the
control switch C527-6, system for normal operation.
circuit CPM23 (GY),
harness side. No
for RH inoperative mirror, REPAIR the circuit. TEST the system for normal operation.
between C622-4, circuit
CPM23 (GY), harness
side and exterior mirror
control switch C527-6,
circuit CPM23 (GY),
harness side.
Is the resistance less than 5

ohms?
PINPOINT TEST B: A SINGLE MIRROR IS INOPERATIVE - NON-MEMORY MIRRORS 280

Pinpoint Test C: A Single Mirror Does Not Function With Switch Logic - Non-Memory Mirrors
Normal Operation
The exterior mirror control switch supplies voltage and ground to control LH and RH exterior mirror motor
movement. Each mirror contains a horizontal and vertical motor. The exterior mirror control switch controls
movement by reversing polarity of the voltage and ground circuits being supplied to each motor.

Exterior mirror
PINPOINT TEST C: A SINGLE MIRROR DOES NOT FUNCTION WITH SWITCH LOGIC - NON-MEMORY MIRRORS

C1 CHECK THE MIRROR MOVEMENT
(LEFT/RIGHT)
Yes
Operate the RH and LH exterior mirrors in GO to C2 .
the right and left direction using the
exterior mirror control switch. No
Do the exterior mirrors move left and GO to C3 .
right?
C2 CHECK THE MIRROR MOVEMENT
(UP/DOWN)
Yes
Operate the RH and LH exterior mirrors in The system is operating correctly at this time.
the up and down direction using the Concern may have been caused by a loose or
exterior mirror control switch. corroded connector. TEST the system for normal
Do the exterior mirrors move up and operation.
down?
No
GO to C4 .
C3 CHECK THE VOLTAGE TO THE
INOPERATIVE MIRROR
Yes
Disconnect: Inoperative Exterior Mirror CHECK the LH or RH exterior mirror jumper
C516 (LH) or C622 (RH) . harness between the vehicle harness and the exterior
NOTE: Position the exterior mirror control mirror motors for open circuits and damaged or
switch to the LH or RH position. pushed-out pins. If the jumper harness is not OK,
While operating the exterior mirror control REPAIR the jumper harness. If the jumper harness
switch in the rightward position, measure cannot be repaired, INSTALL a new LH or RH

the voltage between ground and exterior exterior mirror. REFER to Exterior Mirror in this
mirror: section. If the jumper harness is OK, INSTALL a
LH exterior mirror: C516-5, new exterior mirror motor. REFER to Exterior
circuit CPM16 (BN/BU), harness Mirror Motor in this section. TEST the system for
side. normal operation.
RH exterior mirror: C622-5,
circuit CPM20 (BN/WH), harness No
side. GO to C5 .

INOPERATIVE MIRROR
Yes
Disconnect: Inoperative Exterior Mirror CHECK the LH or RH exterior mirror jumper
C516 (LH) or C622 (RH) . harness between the vehicle harness and the exterior
NOTE: Position the exterior mirror control mirror motors for open circuits and damaged or
switch to the LH or RH position. pushed-out pins. If the jumper harness is not OK,
While operating the exterior mirror control REPAIR the jumper harness. If the jumper harness
switch in the upward position, measure the cannot be repaired, INSTALL a new LH or RH
voltage between ground and exterior exterior mirror. REFER to Exterior Mirror in this
mirror: section. If the jumper harness is OK, INSTALL a
LH exterior mirror: C516-3, new exterior mirror motor. REFER to Exterior
circuit CPM17 (BU/GN), harness Mirror Motor in this section. TEST the system for
RH exterior mirror: C622-3,
circuit CPM21 (YE/VT), harness No
side. GO to C6 .

C5 CHECK THE MIRROR CONTROL
Yes
Disconnect: Exterior Mirror Control Switch INSTALL a new exterior mirror control switch.
C527 . REFER to Exterior Mirror Control Switch in this
LH exterior mirror: Measure the section. TEST the system for normal operation.
resistance between exterior mirror control
switch C527-8, circuit CPM16 (BN/BU), No
harness side and LH exterior mirror REPAIR the circuit. TEST the system for normal
PINPOINT TEST C: A SINGLE MIRROR DOES NOT FUNCTION WITH SWITCH LOGIC - NON-MEMORY
282
C516-6, circuit CPM16 (BN/BU), harness operation.

side.
RH exterior mirror: Measure the

switch C527-7, circuit CPM20 (BN/WH),
harness side and RH exterior mirror
C622-6, circuit CPM20 (BN/WH), harness
side.

C6 CHECK THE MIRROR CONTROL
CIRCUITS FOR AN OPEN FOR AN OPEN
Yes
Disconnect: Exterior Mirror Control Switch INSTALL a new exterior mirror control switch.
C527 . REFER to Exterior Mirror Control Switch in this
LH exterior mirror: Measure the section. TEST the system for normal operation.
switch C527-5, circuit CPM17 (BU/GN), No
harness side and LH exterior mirror REPAIR the circuit. TEST the system for normal
C516-3, circuit CPM17 (BU/GN), harness operation.
side.
RH exterior mirror: Measure the

switch C527-2, circuit CPM21 (YE/VT),
harness side and RH exterior mirror
C622-3, circuit CPM21 (YE/VT), harness
283
side.
Pinpoint Test D: The Memory Mirror is Inoperative
The exterior mirror control switch sends voltage and ground inputs to the Driver Seat Module (DSM) which
controls mirror movement by providing the appropriate voltage and ground polarity to the LH/RH exterior
mirror up/down and left/right motors. The LH and RH exterior mirrors each contain potentiometers for
up/down and left/right position status. The DSM supplies the LH and RH exterior mirror feedback
potentiometers a reference voltage and reference ground. The DSM uses these feedback signals to store/recall
mirror positions.

During self-test, the DSM attempts to operate the exterior mirror motor and uses
B1667 - the motor's position sensor to monitor movement. If no motor movement is
MirroDriver sensed, the DSM disables the output which operates the motor after 250
Up/Down Motor milliseconds and the DTC is set. The DSM will retry motor operation on the
Stalled next activation of the exterior mirror control switch.
B1669 - Mirror
Passenger Up/Down
Motor Stalled
During self-test, the DSM attempts to operate the exterior mirror motor and uses
B1668 - Mirror the motor's position sensor to monitor movement. If no motor movement is
Driver Right/Left sensed, the DSM disables the output which operates the motor after 250
Motor Stalled milliseconds and the DTC is set. The DSM will retry motor operation on the
B1670 - Mirror next activation of the exterior mirror control switch.
Passenger
Right/Left Motor
Stalled
During self-test, if a short to ground or short to battery fault is sensed on the
B1733 - Mirror switch circuit, the DTC is set. During normal operation, if a fault is sensed on
Driver Vertical the circuit for greater than 2 minutes, the DTC is set as continuous. With the
Switch Circuit DTC set, any input signal on the circuit is ignored.
Failu>
B1741 - Mirror
Passenger Vertical
Switch Circuit
Failure
284
B1737 - Mirror During self-test, if a short to ground or short to battery fault is sensed on the
Driver Horizontal switch circuit, the DTC is set. During normal operation , if a fault is sensed on
Switch Circuit the circuit for greater than 2 minutes, the DTC is set as continuous. With the
Failure DTC set, any input signal on the circuit is ignored.
B1745 - Mirror
Passenger
Horizontal Switch
Circuit Failure
Short to ground or battery detected by the DSM .
B2223 - Mirror
Driver Drive Circuit
Failure
B2224 - Mirror
Passenger Drive
Circuit Failure
Open or short to ground detected by the DSM . When DTC is set DSM operates
B2312 - Mirror motor for 1 second then movement stops.
Passenger
Horizontal
Feedback
Potentiometer
Circuit Failure
B2320 - Mirror
Driver Horizontal
Feedback
Potentiometer
Circuit Failure
Short to battery detected by the DSM . When DTC is set DSM operates motor
B2314 - Mirror for 1 second then movement stops.
Passenger
Horizontal
Feedback
Potentiometer
Circuit Short to
Battery
B2322 - Mirror
Driver Horizontal
Feedback
Potentiometer
Circuit Short to
Battery
Open or short to ground detected by the DSM . When DTC is set DSM operates
B2316 - Mirror motor for 1 second then movement stops.
Passenger Vertical
Feedback
Potentiometer
Circuit Failure
B2324 - Mirror
Driver Vertical
Feedback
Potentiometer
Circuit Failure
285
B2318 - Mirror Short to battery detected by the DSM . When DTC is set DSM operates motor
Passenger Vertical for 1 second then movement stops.
Feedback
Potentiometer
Circuit Short to
Battery
B2326 - Mirror
Driver Vertical
Feedback
Potentiometer
Circuit Short to
Battery
This pinp intended to diagnose the following:

Fuse
Exterior mirror
DSM
PINPOINT TEST D: THE MEMORY MIRROR IS INOPERATIVE

D1 RETRIEVE THE DTCs FROM THE DSM
Yes
Ignition ON. If DTC B1667 or B1668 is present with other
Enter the following diagnostic mode on the scan DTCs, DIAGNOSE the other DTCs first.
tool: Self Test - DSM .
Are any DTCs retrieved? If DTC B1667 or B1668 is present with no
other DTCs, INSPECT the LH exterior mirror
motor for foreign material, damage or a
binding condition. If no condition is found, GO
to D10 .
If DTC B1669 or B1670 is present with

otheDTCs, DIAGNOSE the other DTCs first.
If DTC B1669 or B1670 is present with no

other DTCs, INSPECT the RH exterior mirror
motor for foreign material, damage or a
binding condition. If no condition is found, GO
to D12 .
For DTCs B1733, B1737, B1741 or B1745,

GO to D14 .
For DTC B2223, GO to D17 .
PINPOINT TEST D: THE MEMORY MIRROR IS INOPERATIVE 286

For DTC B2224, GO to D19 .
For DTCs B2312, B2316, B2320 or B2324,

GO to D21 .
For DTCs B2314, B2318, B2322 or B2326,

GO to D24 .
For all other DSM DTCs, REFER to Section

501-10 .
No
GO to D2 .
D2 CHECK OPERATION OF THE MIRRORS
FROM THE EXTERIOR MIRROR CONTROL
SWITCH
Yes
Operate the mirrors using the exterior mirror If the LH OR RH exterior mirror operates
control switch. correctly in at least one direction GO to D9 .
Do the LH or RH mirrors operate using the
exterior mirror control switch? No
If both the LH and RH exterior mirrors are
inoperative, GO to D3 .
D3 CHECK THE EXTERIOR MIRROR
CONTROL SWITCH
Yes
Disconnect: Exterior Mirror Control Switch
C527. No
Carry out the Exterior Mirror Control Switch INSTALL a new exterior mirror control
Component Test. switch. REFER to Exterior Mirror Control
Switch in this section. TEST the system for
Refer to Wiring Diagrams Cell 149 for normal operation.
component testing.
Did the exterior mirror control switch pass
the component test?
D4 CHECK FOR VOLTAGE TO THE
EXTERIOR MIRROR CONTROL SWITCH
Yes
Measure the voltage between exterior mirror GO to D5 .
control switch C527-1, circuit SBP12 (GN/RD),
VERIFY that Smart Junction Box (SJB) fuse
12(7.5A) is OK. If OK, REPAIR the circuit. If
not OK, REFER to the Wiring Diagrams
manual to identify the possible causes of the
circuit short. TEST the system for normal
operation.


D5 CHECK FOR GROUND TO THE EXTERIOR
Yes
Measure the resistance between exterior mirror GO to D6 .
control switch C527-3, circuit GD133 (BK),
normal operation.

D6 CHECK THE MIRROR SWITCH COMMON
CIRCUIT FOR A SHORT TO VOLTAGE
Yes
Disconnect: DSM C341D. REPAIR the circuit. TEST the system for
Ignition ON. normal operation.
Measure the voltage between exterior mirror
control switch C527-6, circuit CPM23 (GY), No
harness side and ground. GO to D7 .

CIRCUIT FOR A SHORT TO GROUND
Yes
control switch C527-6, circuit CPM23 (GY) No
harness side and ground. REPAIR the circuit. TEST the system for
normal operation.


CIRCUIT FOR AN OPEN
Yes
Measure the resistance between DSM GO to D25 .
C341D-16, circuit CPM23 (GY), harness side
and exterior mirror control switchC527-6, No
circuit CPM23 (GY), harness side. REPAIR the circuit. TEST system for normal
operation.

D9 CHECK THE EXTERIOR MIRROR SWITCH
Yes
Disconnect: Exterior Mirror Control Switch GO to D25 .
C527.
Disconnect: DSM C341D. No
Measure the resistance between exterior mirror REPAIR the circuit(s). CLEAR the DTCs.
control switch C527, harness side and DSM REPEAT the self-test. TEST the system for
C341D, harness side using the following chart: normal operation.
Exterior Mirror
Switch Circuit DSM
C527-8 CPM15 C341D-20
(VT/OG)
C527-5 CPM14 C341D-19
(GY/BN)
C527-7 CPM19 C341D-18
(GY/OG)
C527-2 CPM18 C341D-17
(GN/BN)

D10 CHECK THE LH EXTERIOR MIRROR FOR

VOLTAGE WHILE COMMANDING THE DSM
PIDs
Yes
Disconnect: LH Exterior Mirror C516. CHECK the LH exterior mirror jumper harness
Enter the following diagnostic mode on the scan between the vehicle harness and the exterior
tool: DataLogger - DSM . mirror motors for open circuits and damaged or
DTC B1667: Measure the voltage between pushed-out pins. If the jumper harness is not
ground and LH exterior mirror: OK, REPAIR the jumper harness. If the jumper
C516-3, circuit CPM29 (GN), harness harness cannot be repaired, INSTALL a new
side while toggling the DSM PID LH exterior mirror. REFER to Exterior Mirror
Driver's Mirror Up (DR_UP) to On. in this section. If the jumper harness is OK,
C516-4, circuit CPM26 (WH), harness INSTALL a new LH exterior mirror motor.
side while toggling the DSM PID REFER to Exterior Mirror Motor in this
Driver's Mirror Down (DR_DOWN) to section. CLEAR the DTCs. REPEAT the
On. self-test. TEST the system for normal
DTC B1668: Measure the voltage between operation.
ground and LH exterior mirror:
C516-4, circuit CPM26 (WH), harness No
side while toggling the DSM PID GO to D11 .
Driver's Mirror Left (DR_LEFT) to On.
C516-5, circuit CPM28 (BU/BN),
harness side while toggling the DSM
PID Driver's Mirror Right
(DR_RIGHT) to On.
Do the voltages momentarily change from 0

volts to greater than 10 volts when the active
command is toggled ON?
D11 CHECK THE LH EXTERIOR MIRROR
CONTROL OUTPUT CIRCUITS FOR AN OPEN
Yes
Disconnect: DSM C341D.
Measure the resistance between LH exterior No
mirror C516, harness side and DSM C341D, REPAIR the affected circuit(s). CLEAR the
harness side using the following chart: DTCs. REPEAT the self-test. TEST the system
for normal operation.
LH Exterior
DTC Mirror Circuit DSM
B1667 C516-3 CPM29 (GN) C341D-4
B1667 C516-4 C341D-2

CPM26
(WH)
B1668 C516-4 CPM26 C341D-2
(WH)
B1668 C516-5 CPM28 C341D-5
(BU/BN)

D12 CHECK THE RH EXTERIOR MIRROR FOR
VOLTAGE WHILE COMMANDING THE DSM
PIDs
Yes
Disconnect: RH Exterior Mirror C622. CHECK the RH exterior mirror jumper harness
Enter the following diagnostic mode on the scan between the vehicle harness and the exterior
tool: DSM DataLogger. mirror motors for open circuits and damaged or
DTC B1669: Measure the voltage between pushed-out pins. If the jumper harness is not
ground and RH exterior mirror: OK, REPAIR the jumper harness. If the jumper
C622-3, circuit CPM34 (WH/BN), harness cannot be repaired, INSTALL a new
harness side while toggling the DSM RH exterior mirror. REFER to Exterior Mirror
PID Passenger's Mirror Up (PR_UP) to in this section. If the jumper harness is OK,
On. INSTALL a new exterior mirror motor.
C622-4, circuit CPM31 (YE/GY), REFER to Exterior Mirror Motor in this
harness side while toggling the DSM section. CLEAR the DTCs. REPEAT the
PID Passenger's Mirror Down self-test. TEST the system for normal
(PR_DOWN) to On. operation.
DTC B1670: Measure the voltage between
ground and RH exterior mirror: No
C622-4, circuit CPM31 (YE/GY), GO to D13 .
PID Passenger's Mirror Left
(PR_LEFT) to On.
C622-5, circuit CPM33 (WH/VT),
PID Passenger's Mirror Right
(PR_RIGHT) to On.

Do the voltages momentarily change from 0

volts to greater than 10 volts when the active
command is toggled ON?
D13 CHECK THE RH EXTERIOR MIRROR
CONTROL OUTPUT CIRCUITS FOR AN OPEN
Yes
Measure the resistance between RH exterior No
mirror C622, harness side and DSM C341D, REPAIR the circuit(s). CLEAR the DTCs.
harness side using the following chart: REPEAT the self-test. TEST the system for
normal operation.
RH Exterior
DTC Mirror Circuit DSM
B1669 C622-3 CPM34 C341D-7
(WH/BN)
B1669 C622-4 CPM31 C341D-8
(YE/GY)
B1670 C622-4 CPM31 C341D-8
(YE/GY)
B1670 C622-5 CPM33 C341D-6
(WH/VT)

CONTROL SWITCH
Yes
Disconnect: Exterior Mirror Control Switch GO to D15 .
C527.
Carry out the Exterior Mirror Control Switch No
component test. INSTALL a new exterior mirror control
switch. REFER to Exterior Mirror Control
Refer to Wiring Diagrams Cell 149 for Switch in this section. CLEAR the DTCs.
component testing. REPEAT the self-test. TEST the system for
Did the exterior mirror control switch pass normal operation.
the component test?
D15 CHECK THE MIRROR CONTROL
CIRCUITS FOR A SHORT TO VOLTAGE

Ignition OFF. Yes

Disconnect: DSM C341D. REPAIR the circuit. CLEAR the DTCs.
Ignition ON. REPEAT the self-test. TEST the system for
Measure the voltage between exterior mirror normal operation.
control switch C527, harness side and ground
GO to D16 .
Exterior Mirror
DTC Control Switch Circuit
B1733 C527-5 CPM14
(GY/BN)
B1737 C527-8 CPM15
(VT/OG)
B1741 C527-2 CPM18
(GN/BN)
B1745 C527-7 CPM19
(GY/OG)

SWITCH CIRCUITS FOR A SHORT TO GROUND
Yes
control switch C527, harness side and ground No
using the following chart: REPAIR the affected circuit(s). CLEAR the
DTCs. REPEAT the self-test. TEST the system
Exterior Mirror
DTC Control Switch Circuit
B1733 C527-5 CPM14
(GY/BN)
B1737 C527-8 CPM15
(VT/OG)
B1741 C527-2 CPM18
(GN/BN)
B1745 C527-7 CPM19
(GY/OG)


CONTROL OUTPUT CIRCUITS FOR A SHORT
TO VOLTAGE
Yes
Ignition OFF. REPAIR the affected circuit(s). CLEAR the
Disconnect: LH Exterior Mirror C516. DTCs. REPEAT the self-test. TEST the system
Disconnect: DSM C341D. for normal operation.
Ignition ON.
Measure the voltage between LH exterior No
mirror, harness side and ground using the GO to D18 .
following chart:
LH Exterior Mirror Circuit

C516-3 CPM29 (GN)
C516-4 CPM26 (WH)
C516-5 CPM28 (BU/BN)

TO GROUND
Yes
Ignition OFF. CHECK the LH exterior mirror jumper harness
Measure the resistance between LH exterior between the vehicle harness and the exterior
mirror, harness side and ground using the mirror motors for shorted circuits or damaged
following chart: and pushed-out pins. If the jumper harness is
not OK, REPAIR the jumper harness. If the
jumper harness cannot be repaired, INSTALL a
new exterior mirror. REFER to Exterior Mirror
in this section. If the jumper harness is OK,

LH Exterior Mirror Circuit INSTALL a new exterior mirror motor.

C516-3 CPM29 (GN) REFER to Exterior Mirror Motor in this
section. CLEAR the DTCs. REPEAT the
C516-4 CPM26 (WH) self-test. TEST the system for normal
C516-5 CPM28 (BU/BN) operation.
No
REPAIR the affected circuit(s). CLEAR the
Are the resistances greater than 10,000

ohms?
TO VOLTAGE
Yes
Ignition OFF. REPAIR the circuit(s). CLEAR the DTCs.
Disconnect: RH Exterior Mirror C622. REPEAT the self-test. TEST the system for
Disconnect: DSM C341D. normal operation.
Ignition ON.
Measure the voltage between RH exterior mirror No
C622, harness side and ground using the GO to D20 .
following chart:
RH Exterior Mirror Circuit

C622-3 CPM34 (WH/BN)
C622-4 CPM31 (YE/GY)
C622-5 CPM33 (WH/VT)

TO GROUND

Ignition OFF. Yes

Measure the resistance between RH exterior CHECK the RH exterior mirror jumper harness
mirror C622, harness side and ground using the between the vehicle harness and the exterior
following chart: mirror motors for shorted circuits or damaged
and pushed-out pins. If the jumper harness is
not OK, REPAIR the jumper harness. If the
jumper harness cannot be repaired, INSTALL a
new exterior mirror. REFER to Exterior Mirror
RH Exterior Mirror Circuit in this section. If the jumper harness is OK,
C622-3 CPM34 (WH/BN) INSTALL a new exterior mirror motor.
REFER to Exterior Mirror Motor in this
C622-4 CPM31 (YE/GY) section. CLEAR the DTCs. REPEAT the
C622-5 CPM33 (WH/VT) self-test. TEST the system for normal
operation.
No
REPAIR the circuit(s). CLEAR the DTCs.
REPEAT the self-test. TEST the system for
normal operation.

ohms?
D21 CHECK THE MIRROR POSITION SENSOR
Yes
Disconnect: DTC B2312 or B2316: RH No
Exterior Mirror C622. REPAIR the affected circuit. CLEAR the
Disconnect: DTC B2320 or B2324: LH DTCs. REPEAT the self-test. TEST the system
Exterior Mirror C516. for normal operation.
Measure the resistance between DSM , harness
side and ground using the following chart:
DSM Circuit
C341D-1 LPM30 (GY/VT)
C341D-11 RPM30 (YE)
C341D-12 VPM36 (BN/YE)
C341D-13 VPM35 (YE/BU)
C341D-14 VPM38 (BN/GN)
C341D-15 VPM37 (BU/OG)


ohms?
Yes
Measure the resistance between DSM C341D, GO to D23 .
harness side and exterior mirror C516
(LH)/C622 (RH), harness side using the No
following charts: REPAIR the affected circuit. CLEAR the
DTCs. REPEAT the self test. TEST the system
DTCs B2312 or B2316
RH Exterior
Mirror Circuit DSM
C622-12 LPM30 C341D-1
(GY/VT)
C622-15 RPM30 C341D-11
(YE)
C622-14 VPM38 C341D-14
(BN/GN)
C622-13 VPM37 C341D-15
(BU/OG)
DTCs B2320 or B2324
LH Exterior
DSM Circuit Mirror
C341D-1 LPM30 C516-12
(GY/VT)
C341D-11 RPM30 (YE) C516-15
C341D-12 VPM36 C516-14
(BN/YE)
C341D-13 VPM35 C516-13
(GY/VT)


FEED AND RETURN FROM THE DSM
Yes
Connect: DSM C341D. For DTCs B2312 or B2316, CHECK the RH
Ignition ON. exterior mirror jumper harness between the
For DTCs B2312 or B2316 , measure the vehicle harness and the exterior mirror motors
voltage between RH exterior mirror C622-12, for open or shorted circuits and damaged or
circuit LPM30 (GY/VT), harness side and RH pushed-out pins.
exterior mirror C622-15, circuit RPM30 (YE),
harness side. For DTCs B2320 or B2324, CHECK the LH
For DTCs B2320 or B2324 , measure the exterior mirror jumper harness between the
voltage between LH exterior mirror C516-12, vehicle harness and the exterior mirror motors
circuit LPM30 (GY/VT), harness side and LH for open or shorted circuits and damaged or
exterior mirror C516-15, circuit RPM30 (YE), pushed-out pins.
harness side.
If the jumper harness is not OK, REPAIR the
jumper harness. If the jumper harness cannot
be repaired, INSTALL a new exterior mirror.
REFER to Exterior Mirror in this section. If the
jumper harness is OK, INSTALL a new
exterior mirror motor. REFER to Exterior
Mirror Motor in this section. CLEAR the
Is the voltage approximately 5 volts?
No
GO to D25 .
POSITION SENSOR CIRCUITS FOR A SHORT
TO VOLTAGE
Yes
Disconnect: DSM C341D. DTCs. REPEAT the self-test. TEST the system
Disconnect: DTC B2314 or B2318: RH for normal operation.
Exterior Mirror C622.
Disconnect: DTC B2322 or B2326: LH No
Exterior Mirror C516. For DTCs B2314 or B2318, CHECK the RH
Ignition ON. exterior mirror jumper harness between the
Measure the voltage between exterior mirror vehicle harness and the exterior mirror motors
C516 (LH)/C622 (RH), harness side and ground for open or shorted circuits and damaged or
using the following charts: pushed-out pins.
For DTCs B2322 or B2326, CHECK the LH

exterior mirror jumper harness between the
vehicle harness and the exterior mirror motors
DTCs B2314 or B2318 for open or shorted circuits and damaged or

RH Exterior Mirror Circuit pushed-out pins.

C622-12 LPM30 (GY/VT)
If the jumper harness is not OK, REPAIR the
C622-15 RPM30 (YE) jumper harness. If the jumper harness cannot
C622-14 VPM38 (BN/GN) be repaired, INSTALL a new exterior mirror.
C622-13 VPM37 (BU/OG) REFER to Exterior Mirror in this section. If the
jumper harness is OK, INSTALL a new
exterior mirror motor. REFER to Exterior
Mirror Motor in this section. CLEAR the
DTCs B2322 or B2326 for normal operation.
LH Exterior Mirror Circuit

C516-12 LPM30 (GY/VT)
C516-15 RPM30 (YE)
C516-14 VPM36 (BN/YE)
C516-13 VPM35 (GY/VT)

D25 CHECK THE DSM FOR CORRECT
OPERATION
Yes
Disconnect all DSM connectors. INSTALL a new DSM . REFER to Section
Check for: 501-10 . CLEAR the DTCs. REPEAT the
corrosion self-test. TEST the system for normal
damaged pins operation.
pushed-out pins
Connect all connectors and make sure they seat No
correctly. The system is operating correctly at this time.
Operate the system and verify the concern is Concern may have been caused by a loose or
still present. corroded connector. CLEAR the DTCs.
Is the concern still present? REPEAT the self-test.
Pinpoint Test E: The Power Folding Mirrors Do Not Operate/Do Not Operate Correctly
NOTE: The power folding mirrors must be synchronized anytime the RH, LH or both power folding mirrors
are folded or unfolded without using the power folding mirror control switch, or if a new power folding mirror
has been installed. Refer to Exterior Mirror Motor Synchronization - Power Folding in this section.

Normal Operation
When the power folding mirror module receives a ground signal from the exterior mirror control switch, the
power folding mirror module will activate the power folding mirrors in the opposite direction of the last
activation for approximately 20 seconds. The power folding mirror module controls movement by reversing
the polarity of the voltage and ground it supplies to the power folding mirror motors.
If the power folding mirrors are folded or unfolded continuously (6 to 10 cycles), the power lockout feature
will disable the system for approximately 7-10 minutes to prevent damage to the power fold motors. After
7-10 minutes have elapsed, normal operation will resume.
DTC B112B (Mirror Power Fold Switch Input Short to Battery) - Short to battery on mirror power
fold switch input circuit.
This pinpoint test is intended to diagnose the following: >Wiring, terminals or connectors
Outer glass weatherstrip not fully seated (causing binding in mirror fold pivot)
Exterior mirror
DSM
PINPOINT TEST E: THE POWER FOLDING MIRRORS DO NOT OPERATE/DO NOT OPERATE CORRECTLY
NOTE: Before running a self-test diagnostic or retrieving DTCs, the power fold switch must be inactive for at
least 30 seconds. Retrieving DTCs before 30 seconds will result in false DTCs.

E1 RETRIEVE THE DTCs FROM THE DSM
Yes
Use the recorded DSM DTCs from the continuous and If DTC B112B, GO to E17 .
on-demand self tests.
Are any DTCs retrieved? No
GO to E2 .
E2 CHECK THE OPERATION OF THE POWER
FOLDING MIRRORS
Yes
Position the exterior mirror control switch to the center The system is operating correctly at
position. this time. Concern may have been
Using the exterior mirror control switch, operate the caused by a loose or corroded
power folding mirrors. connector or the power folding mirror
Do the RH and LH power folding mirror operate? power lockout feature may have been
active. TEST the system for normal
operation.
No
If both the LH and RH power folding
mirrors are inoperative, GO to E3 . If
only the LH power folding mirror is
inoperative, GO to E13 . If only the
RH power folding mirror is

inoperative, GO to E15 .
E3 CHECK THE EXTERIOR MIRROR CONTROL
SWITCH
Yes
Disconnect: Exterior Mirror Control Switch C527 .
Carry out the Exterior Mirror Control Switch component No
test. INSTALL a new exterior mirror
control switch. REFER to Exterior
Refer to Wiring Diagrams Cell 149 for component Mirror Control Switch in this section.
testing. TEST the system for normal
Did the exterior mirror control switch pass the operation.
component test?
E4 CHECK THE FOLDING MIRROR CONTROL
Yes
Disconnect: DSM C341C . GO to E5 .
Measure the resistance between exterior mirror control
switch C527-4, circuit CPM22 (GY/BN), harness side No
and ground. REPAIR the circuit.
SYNCHRONIZE the power folding
mirrors. REFER to Exterior Mirror
Motor Synchronization - Power
Folding in this section. TEST the

CIRCUIT FOR AN OPEN
Yes
Measure the resistance between exterior mirror control GO to E6 .
switch C527-4, circuit CPM22 (GY/BN), harness side
and DSM C341C-18, circuiCPM22 (GY/BN), harness No
side. REPAIR the circuit.

E6 CHECK THE POWER FOLDING MIRROR
PINPOINT TEST E: THE POWER FOLDING MIRRORS DO NOT OPERATE/DO NOT OPERATE
301
CORREC
Ignition ON. Yes

Measure the voltage between ground and DSM : GO to E7 .
C341C-2, circuit CPM04 (VT/BN), harness side.
C341C-1, circuit CPM39 (GN/VT), harness side. No
GO to E9 .

E7 CHECK THE LH POWER FOLDING MIRROR FOR A
SHORT TO VOLTAGE
Yes
Ignition OFF. CHECK the LH exterior mirror
Disconnect: LH Exterior Mirror C516 . jumper harness between the vehicle
Ignition ON. harness and the exterior mirror glass
Measure the voltage between ground and DSM : for open circuits and damaged or
C341C-2, circuit CPM04 (VT/BN), harness side. pushed-out pins. If the jumper harness
C341C-1, circuit CPM39 (GN/VT), harness side. is not OK, REPAIR the jumper
harness. If the jumper harness cannot
be repaired, INSTALL a new LH
exterior mirror. REFER to Exterior
Mirror in this section.
No
GO to E8 .
E8 CHECK THE RH POWER FOLDING MIRROR FOR A
SHORT TO VOLTAGE
Yes
Ignition OFF. REPAIR the circuit(s).
Disconnect: RH Exterior Mirror C622 . SYNCHRONIZE the power folding
Ignition ON. mirrors. REFER to Exterior Mirror
Measure the voltage between ground and DSM : Motor Synchronization - Power
C341C-2, circuit CPM04 (VT/BN), harness side. Folding in this section. TEST the
C341C-1, circuit CPM39 (GN/VT), harns side. system for normal operation.
No
CHECK the RH exterior mirror
jumper harness between the vehicle
harness and the exterior mirror glass
for open circuits and damaged or
pushed-out pins. If the jumper harness
is not OK, REPAIR the jumper
be repaired, INSTALL a new RH
302
CORREC

system normal operation.
E9 CHECK THE POWER FOLDING MIRROR
Yes
Measure the resistance between ground and DSM : GO to E12 .
C341C-2, circuit CPM04 (VT/BN), harness side.
C341C-1, circuit CPM39 (GN/VT), harness side. No
GO to E10 .

E10 CHECK THE LH POWER FOLDING MIRROR FOR
A SHORT TO GROUND
Yes
Disconnect: LH Exterior Mirror C516 . GO to E11 .
Measure the resistance between ground and DSM :
C341C-2, circuit CPM04 (VT/BN), harness side. No
C341C-1, circuit CPM39 (GN/VT), harness side. CHECK the LH exterior mirror
be repaired, INSTALL a new LH
E11 CHECK THE RH POWER FOLDING MIRROR FOR
A SHORT TO GROUND
Yes
Disconnect: RH Exterior Mirror C622 . REPAIR the circuit(s).
Measure the resistance between ground and DSM : SYNCHRONIZE the power folding
C341C-2, circuit CPM04 (VT/BN), harness side. mirrors. REFER to Exterior Mirror
C341C-1, circuit CPM39 (GN/VT), harness side. Motor Synchronization - Power
303
CORREC
No
CHECK the RH exterior mirror
be repaired, INSTALL a new RH
E12 CHECK THE POWER FOLD EXTERIOR MIRROR
Yes
Measure the resistance between exterior mirror: GO to E19 .
C516-7, circuit CPM04 (VT/BN), harness side
and DSM C341C-2, circuit CPM04 (VT/BN), No
harness side. REPAIR the circuit(s).
C516-16, circuit CPM39 (GN/VT), harness side SYNCHRONIZE the power folding
and DSM C341C-1, circuit CPM39 (GN/VT), mirrors. REFER to Exterior Mirror
harness side. Motor Synchronization - Power

E13 CHECK LH POWER MIRROR FOR IMPROPERLY
INSTALLED OUTER GLASS WEATHERSTRIP (BELT
MOLDING)
Yes
NOTICE: Wait at least 4 minutes after removing the REINSTALL the LH exterior mirror.
mirror and attempting to operate it. This allows the TEST the system for normal
mirror fold pivot to relax and removes the potential operation.
binding condition. Failure to follow this instruction
may result in unnecessary mirror replacement. No
GO to E14 .
NOTE: With the mirror installed the unseated portion of
the outer glass weatherstrip may not be visible.
Ignition OFF.
Remove the LH exterior mirror and inspect the outer
glass weatherstrip for correct installation. Refer to
Exterior Mirror in this section.
304
CORREC
Reconnect the LH exterior mirror without installing it.

Synchronize the power folding mirrors. Refer to
href="SBJ~us~en~file=SBJ19005.HTM~gen~ref.HTM"
>Exterior Mirror Motor Synchronization - Power Folding
in this section.
Ignition ON.
Test the LH exterior mirror for normal power fold
operation.
Does the LH exterior mirror operate normally?
E14 CHECK THE LH POWER FOLD EXTERIOR
MIRROR CIRCUIT FOR AN OPEN
Yes
Ignition OFF. CHECK the LH exterior mirror
Disconnect: LH Exterior Mirror C516 . jumper harness between the vehicle
Disconnect: DSM C341C . harness and the exterior mirror glass
Measure the resistance between exterior mirror: for open circuits and damaged or
C516-7, circuit CPM04 (VT/BN), harness side pushed-out pins. If the jumper harness
and DSM C341C-2, circuit CPM04 (VT/BN), is not OK, REPAIR the jumper
harness side. harness. If the jumper harness cannot
C516-16, circuit CPM39 (GN/VT), harness side be repaired, INSTALL a new LH
and DSM C341C-1, circuit CPM39 (GN/VT), exterior mirror. REFER to Exterior
hness side. Mirror in this section.
Folding in this section. REPEAT the
self-test.
No
REPAIR the circuit(s).
system normal operation.
E15 CHECK RH POWER MIRROR FOR IMPROPERLY
INSTALLED OUTER GLASS WEATHERSTRIP (BELT
MOLDING)
Yes
NOTICE: Wait at least 4 minutes after removing the REINSTALL the RH exterior mirror.
mirror and attempting to operate it. This allows the TEST the system for normal
mirror fold pivot to relax and removes the potential operation.
binding condition. Failure to follow this instruction
may result in unnecessary mirror replacement. No
GO to E16 .
NOTE: With the mirror installed the unseated portion of
the outer glass weatherstrip may not be visible.
Ignition OFF.
Remove the RH exterior mirror and inspect the outer
glass weatherstrip for correct installation. Refer to
Exterior Mirror in this section.
Reconnect the RH exterior mirror without installing it.
305
CORREC
Synchronize the power folding mirrors. Refer to Exterior

Mirror Motor Synchronization - Power Folding in this
section.
Ignition ON.
Test the RH exterior mirror for normal power fold
operation.
Does the RH exterior mirror operate normally?
E16 CHECK THE RH POWER FOLD EXTERIOR
MIRROR CIRCUIT FOR AN OPEN
Yes
Ignition OFF. CHECK the RH exterior mirror
Disconnect: RH Exterior Mirror C622 . jumper harness between the vehicle
Disconnect: DSM C341C . harness and the exterior mirror glass
Measure the resistance between exterior mirror: for open circuits and damaged or
C622-7, circuit CPM04 (VT/BN), harness side pushed-out pins. If the jumper harness
and DSM C341C-2, circuit CPM04 (VT/BN), is not OK, REPAIR the jumper
harness side. harness. If the jumper harness cannot
C622-16, circuit CPM39 (GN/VT), harness side be repaired, INSTALL a new RH
and DSM C341C-1, circuit CPM39 (GN/VT), exterior mirror. REFER to Exterior
harness side. Mirror in this section.
No
Yes
Disconnect: Exterior Mirror Control Switch C527 .
Disconnect: DSM C341C . No
Measure the voltage between DSM C341C-18, circuit REPAIR the circuit. CLEAR the
CPM22 (GY/BN), harness side and ground. DTCs. SYNCHRONIZE the power
folding mirrors. REFER to Exterior
Mirror Motor Synchronization -
Power Folding in this section. TEST
src="SBJ~us~en~file=N0091980.jpg~gen~ref.jpg" the system for normal operation.
height="211" width="325" border="0">
E18 CHECK THE EXTERIOR MIRROR CONTROL
SWITCH
Yes
Carry out the Exterior Mirror Control Switch component GO to E19 .
test.
No
306
CORREC
Refer to Wiring Diagrams Cell 149 for component teing. INSTALL a new exterior mirror
Did the exterior mirror control switch pass the control switch. REFER to Exterior
component test? Mirror Control Switch in this section.
CLEAR the DTCs. SYNCHRONIZE
the power folding mirrors. REFER to
Exterior Mirror Motor
Synchronization - Power Folding in
this section. TEST the system for
normal operation.
E19 CHECK THE DSM FOR CORRECT OPERATION
Yes
Disconnect all DSM connectors. INSTALL a new DSM . REFER to
Check for: Section 501-10 . CLEAR the DTCs.
corrosion. SYNCHRONIZE the power folding
pushed-out pins. mirrors. REFER to Exterior Mirror
Connect all DSM connectors and make sure they seat Motor Synchronization - Power
correctly. Folding in this section. TEST the
Operate the system and verify the concern is still present. system for normal operation.
No
The system is operating correctly at
this time. Concern may have been
connector or the power folding mirror
power lockout feature may have been
active. CLEAR the DTCs. TEST the
Pinpoint Test F: The Heated Exterior Mirror is Inoperative
Refer to Wiring Diagrams Cell 56 , Heated Window for schematic and connector information.
Normal Operation
When the rear window defrost switch is pressed to the ON position, the rear window defrost relay closes and
voltage is supplied to to Battery Junction Box (BJB) fuse 59 (15A). The heated exterior mirrors receive
voltage from BJB fuse 59 (15A).

Fuse
Exterior mirror
PINPOINT TEST F: THE HEATED EXTERIOR MIRROR IS INOPERATIVE


F1 CHECK THE OPERATION OF
THE HEATED EXTERIOR MIRROR
GLASS
Yes
Start the engine. The system is operating correctly at this time.
Press the rear window defrost
switch to the ON position. No
Using an infrared temperature GO to F2 .
gun, measure the temperature of
the exterior mirror glass for
approximately 30 seconds noting
changes in temperature.
Does the temperature of the
exterior glass rise?
F2 CHECK THE OPERATION OF
THE REAR WINDOW DEFROST
SYSTEM
Yes
Using an infrared temperature GO to F3 .
gun, measure the temperature of
the rear window for No
approximately 30 seconds noting REFER to Section 501-11 to diagnose the rear window
changes in the temperature. defrost system.
Does the temperature of the
rear window rise?
F3 CHECK THE VOLTAGE TO
THE EXTERIOR MIRRORS
Yes
Disconnect: Exterior Mirror C516
(LH) and C622 (RH) . No
Start the engine. VERIFY that BJB fuse 59 (15A) is OK. If OK, REPAIR the
With the engine running, depress circuit. If not OK, REFER to the Wiring Diagrams manual to
the heated rear window switch to identify the possible causes of the circuit short. TEST the
the ON position. system for normal operation.
Measure the voltage between
ground and inoperative exterior
mirror:
LH exterior mirror:
C516-8, circuit CBB59
(BN/WH), harness side.
RH exterior mirror:
C622-8, circuit CBB59
(BN/WH), harness side.
PINPOINT TEST F: THE HEATED EXTERIOR MIRROR IS INOPERATIVE 308

Is the voltage greater than 10

volts?
F4 CHECK THE EXTERIOR
MIRROR GROUND CIRCUIT FOR
AN OPEN
Yes
Ignition OFF. CHECK the RH or LH exterior mirror jumper harness
Measure the resistance between between the vehicle harness and the exterior mirror glass for
ground and inoperative exterior open circuits and damaged or pushed-out pins. If the jumper
mirror: harness is not OK, REPAIR the jumper harness. If the jumper
LH exterior mirror: harness cannot be repaired, INSTALL a new exterior mirror.
C516-2, circuit GD143 REFER to Exterior Mirror in this section. If the jumper
(BK/VT), harness side. harness is OK, INSTALL a new exterior mirror glass. REFER
RH exterior mirror: to Exterior Mirror Glass in this section. TEST the system for
C622-2, circuit GD138 normal operation.
(BK/WH), harness side.
No
REPAIR the circuit. TEST the system for normal operation.

ohms?
PINPOINT TEST F: THE HEATED EXTERIOR MIRROR IS INOPERATIVE 309

Rear View Mirrors - Interior
Special Tool(s)
Flex Probe Kit

NUD105-R025D or equivalent


Interior Auto-Dimming Rear View Mirror
The interior auto-dimming rear view mirror and LH exterior mirror automatically reduces the glare caused by
headlamps reflecting in the interior rear view mirror. The auto-dimming feature is disabled when the vehicle
is in REVERSE. Power is supplied to the interior auto-dimming mirror when the ignition is in the RUN
position or the accey delay is active.
The interior auto-dimming rear view mirror has 2 photoelectric sensors, a forward facing sensor and a
rearward facing sensor, that detect forward and rearward light conditions. Based on these inputs, the automatic
dimming feature adjusts the reflectance level of the interior and LH exterior mirror glass to eliminate
unwanted glare. The reflectance level of the mirror glass is variable and depends on the amount of rear glare
in relation to ambient light conditions in front of the interior mirror.
When the forward sensor detects daytime conditions, the rearward sensor is inactive and the interior rear view
mirror stays in a high reflectance mode. When the forward sensor detects nighttime conditions, the rearward
sensor is active and detects glare from the headlights of vehicles approaching from the rear or other
glare-producing light sources. To provide increased visibility when backing up, the interior rear view mirror
and LH exterior mirror will automatically return to a high reflectance mode whenever the vehicle is in
REVERSE.
If the forward or rearward sensors are blocked, the interior auto-dimming feature might not work correctly.
Interior Rear View Mirror With Video Display
For vehicles that are equipped with a rear-mounted object detection camera, a video image will be displayed
on the LH side of the interior rear view mirror glass when the transmission is in the REVERSE position. For
information on the rear-mounted object detection system, refer to Section 413-13 .
Rear View Mirrors - Interior 310

Interior rear Smart Junction Box (SJB) fuse 41
view mirror (15A)
Interior auto-dimming rear view
mirror
4. If the concern is not visually evident, verify the symptom and GO to Symptom Chart - Interior Mirror
or GO to Symptom Chart - NVH .
Symptom Chart - Interior Mirror
Symptom Chart - Interior Mirror
Symptom Chart - NVH
Symptom Chart - NVH

elimination type of diagnostic approach to pinpoint the responsible system. If this he causal system for the
symptom, refer back to Section 100-04 for the next likely system and continue diagnosis.
The interior mirror vibrates/loose
Interior mirror mounting loose
If the mirror is still on the windshield do not remove. ATTEMPT to fully seat the mirror first. If the
mirror is still loose or vibrates, REMOVE the mirror. REFER to Interior Rear View Mirror in this
section. INSPECT the interior mirror mount for damage. If damaged, INSTALL a new interior mirror.
If the mount is not damaged, REINSTALL the interior mirror making sure that it is fully seated.
Pinpoint Tests
Rear View Mirrors - Interior 311

Pinpoint Test G: The Auto-Dimming Mirror Does Not Operate Correctly
Normal Operation
The interior auto-dimming mirror contains 2 photoelectric sensors: one in the front of the interior rear view
mirror and one mounted on the glass side of the mirror. If the sensors are blocked, the LH exterior mirror and
auto-dimming feature may not operate correctly. Always verify both sensors are not physically blocked before
attempting to diagnose auto-dimming mirror concerns. Whenever the gear selector lever is placed in
REVERSE, the interior auto-dimming mirror temporarily disables the auto-dimming feature. The
auto-dimming feature is enabled again when the gear selector lever is moved out of REVERSE.
If equipped with a LH auto-dimming mirror, voltage is sent from the interior auto-dimming mirror to the LH
exterior mirror.

Fuse
Interior mirror
LH exterior mirror glass
LH exterior mirror
PINPOINT TEST G: THE AUTO-DIMMING MIRROR DOES NOT OPERATE CORRECTLY
NOTE: If the Transmission Range (TR) sensor is malfunctioning and the backup lamps are on all the time or
do not turn on, the interior auto-dimming mirror will not darken or return to normal view.

G1 CHECK OPERATION OF THE
BACKUP LAMPS
Yes
Ignition ON. If the LH exterior mirror only does not dim correctly, GO
Move the gear selector lever through to G10 . If the LH exterior mirror and the interior
the entire range. auto-dimming mirror does not dim correctly, GO to G2 .
Do the backup lamps illuminate
and only in REVERSE? No
REFER to Section 417-01 to diagnose the backup lamps.
G2 VERIFY THE FORWARD AND
REARWARD FACING SENSORS ARE
NOT BLOCKED
Yes
Verify the forward and rearward If possible, REMOVE the blockage. TEST the system for
facing sensors are not blocked. normal operation. If the blockage cannot be removed,
Sources of blockage can include: ADVISE the customer of the correct operation of the
stickers, window decals or interior auto-dimming mirror.
tags.

fold-down screens for TVs No

or DVD players. GO to G3 .
non-OEM window tinting.
Were either of the sensors
blocked?
INTERIOR AUTO-DIMMING MIRROR
- DAYLIGHT CONDITIONS
Yes
Ignition ON. GO to G4 .
Use a bright lamp to illuminate the
forward facing sensor. The mirror No
should adjust to a high reflectance INSTALL a new interior auto-dimming mirror. REFER to
mode (mirror will be clear). Interior ar View Mirror in this section. TEST the system
Does the mirror adjust to the high

reflectance (clear) mode?
- NIGHTTIME CONDITIONS WITH
GLARE
Yes
NOTE: Covering the sensor with a
finger or hand is not adequate. No
Simulate nighttime conditions with GO to G7 .
glare:
cover the forward sensor
with black electrical tape or
other dark material.
illuminate the rearward
facing sensor. The mirror
should darken to a lower
reflectance mode.
Did the mirror darken to a lower

reflectance (darker) mode?
PINPOINT TEST G: THE AUTO-DIMMING MIRROR DOES NOT OPERATE CORRECTLY 313

- NIGHTTIME CONDITIONS
WITHOUT GLARE
Yes
GO to G6 .
No
GO to G7 .
- NIGHTTIME CONDITIONS WITH
THE VEHICLE IN REVERSE
Yes
Ignition ON. The system is operating normally at this time. ADVISE the
NOTE: Covering the sensor with a customer of the correct operation of the interior
finger or hand is not adequate. auto-dimming mirror.
Simulate nighttime conditions with
glare: No
cover the forward sensor GO to G7
with black electrical tape or
other dark material.
facing sensor. (mirror should
darken at this time).
r>
Select REVERSE.
Did the mirror adjust to a high
reflectance (clear) mode?
G7 CHECK FOR VOLTAGE TO THE
Yes
Disconnect: Interior Mirror C911
(without navigation system/video No
display)/C9012 (with navigation VERIFY SJB fuse 41 (15A) is OK. If OK, REPAIR the
system)/C9039 (with video display) . circuit. If not OK, REFER to the Wiring Diagrams manual
Ignition ON. to identify the possible causes of the circuit short. TEST
Without microphone: Measure the the system for normal operation.
voltage between ground and interior
auto-dimming mirror C911-1, circuit
CBP41 (BU), harness side.
With microphone: Measure the

auto-dimming mirror C9012-1,
circuit CBP41 (BU), harness side.
With video display: Measure the

circuit CBP41 (BU), harness side.

volts?
G8 CHECK FOR GROUND TO THE
Yes
Without microphone: Measure the
resistance between interior No
auto-dimming mirror C911-3, circuit REPAIR the circuit. TEST the system for normal
GD133 (BK), harness side and operation.
ground.

resistance between interior
circuit GD133 (BK), harness side
and ground.

circuit GD133 (BK), harness side
and ground.

ohms?
G9 CHECK FOR VOLTAGE TO THE
REVERSE CIRCUIT
Yes
Ignition ON. INSTALL a new interior auto-dimming mirror. REFER to
Select REVERSE. Interior Rear View Mirror in this section. TEST the system
Without microphone: Measure the for normal operation.
voltage between interior
auto-dimming mirror C911-2, circuit No
CLS10 (GN/BN), harness side and REPAIR the circuit. TEST the system for normal
ground. operation.


circuit CLS10 (GN/BN), harness
side and ground.

circuit CLS10 (GN/BN), harness
side and ground.

volts?
G10 CHECK THE INTERIOR
AUTO-DIMMING MIRROR OUTPUT
TO THE LH EXTERIOR REAR VIEW
MIRROR
Yes
Disconnect: LH Exterior Rear View
Mirror C516. No
NOTE: Covering the sensor with a
finger or hand is not adequate.
Simulate nighttime conditions with
glare:
cover the forward facing
sensor with black electrical
tape or other dark material.
facing sensor. The interior
mirror should darken to a
lower reflectance mode.
Measure the voltage between LH

exterior mirror C516-1, circuit
LRD12 (BU/GY), harness side and
ground.
Is the voltage greater than 1 volt?

G11 CHECK THE INTERIOR
AUTO-DIMMING MIRROR GROUND
CIRCUIT TO THE LH EXTERIOR
REAR VIEW MIRROR FOR A SHORT
TO VOLTAGE
Yes
Measure the voltage between LH GO to G12 .
exterior rear view mirror C516-9,
circuit RRD12 (BN), harness side No
and ground. GO to G13 .

G12 ISOLATE THE SHORT TO
VOLTAGE ON THE GROUND
CIRCUIT
Yes
Ignition OFF. REPAIR the circuit. TEST the system for normal
Disconnect: Interior Auto-Dimming operation.
Mirror With Microphone C9012.
Disconnect: Interior Auto-Dimming No
Mirror With Video DisplayC9039. INSTALL a new interior auto-dimming mirror. REFER to
Ignition ON. Interior Rear View Mirror in this section. TEST the system
Measure the voltage between LH for normal operation.
exterior mirror C516-9, circuit
RRD12 (BN), harness side and

ground.

G13 CHECK THE GROUND CIRCUIT
FOR AN OPEN
Yes
Measure the voltage between LH CHECK the LH exterior mirror jumper harness between
exterior mirror C516-1, circuit the vehicle harness and the exterior mirror glass for
LRD12 (BN), harness side and LH shorted or open circuits and damaged or pushed-out pins.
exterior mirror C516-9, circuit If the jumper harness is not OK, REPAIR the jumper
RRD12 (BN), harness side. harness. If the jumper harness cannot be repaired,
INSTALL a new LH exterior mirror. REFER to Exterior
Mirror in this section. If the jumper harness is OK,
INSTALL a new LH exterior mirror glass. REFER to
Exterior Mirror Glass in this section. TEST the system for
normal operation.
No
GO to G14 .
Is the voltage greater than 1 volt?

G14 CHECK THE GROUND CIRCUIT
BETWEEN THE EXTERIOR REAR
VIEW MIRROR AND INTERIOR
AUTO-DIMMING MIRROR FOR AN
OPEN
Yes
Ignition OFF. INSTALL a new interior auto-dimming mirror. REFER to
Disconnect: Interior Auto-Dimming Interior Rear View Mirror in this section. TEST the system
Mirror With Microphone C9012. for normal operation.
Disconnect: Interior Auto-Dimming
Mirror With Video DisplayC9039. No
With microphone: measure the REPAIR the circuit for an open. TEST the system for
resistance between interior normal operation.
circuit RRD12 (BN), harness side
and LH exterior mirror C516-9,
circuit RRD12 (BN), harness side.
With video display: measure the

circuit RRD12 (BN), harness side
and LH exterior mirror C516-9,
circuit RRD12 (BN), harness side.

G15 CHECK THE CIRCUIT
AUTO-DIMMING MIRROR FOR AN
OPEN
Yes
Disconnect: Interior Auto-Dimming
Mirror With Microphone C9012. No
Disconnect: Interior Auto-Dimming REPAIR the circuit. TEST the system for normal
Mirror With Video DisplayC9039. operation.
With microphone: measure the
circuit LRD12 (BU/GY), harness
side and LH exterior mirror C516-1,
side.
With video display: measure the


side and LH exterior mirror C516-1,
side.

G16 CHECK THE CIRCUIT
AUTO-DIMMING MIRROR FOR A
SHORT TO GROUND
Yes
Measure the resistance between LH INSTALL a new interior auto-dimming mirror. REFER to
exterior mirror C516-1, circuit Interior Rear View Mirror in this section. TEST the system
LRD12 (BU/GY), harness side and for normal operation.
ground.
No
REPAIR the circuit. TEST the system for normal
operation.
Is the resistance greater than

10,000 ohms?
Exterior Mirror Motor Synchronization - Power Folding
NOTE: The power folding mirrors must be synchronized anytime the mirrors are folded or unfolded without
using the exterior mirror control switch, or if a new power folding mirror is installed.
NOTE: If the power folding mirrors are electronically folded or unfolded continuously (6 to 10 cycles), the
power lockout feature will disable the system for 7-10 minutes to prevent damage to the power fold motors.
After 7-10 minutes have elapsed, normal operation will resume.
1. Position the exterior mirror control switch to the CENTER position.
NOTE: It may be necessary to cycle the power folding mirrors in or out up to 4 times before they are
synchronized.
2. Press the exterior mirror control switch rearward to the FOLD/UNFOLD position and cycle the power
folding mirrors in and out 4 times.
3. When an audible popping sound is heard, the power folding mirror motors are synchronized.
Exterior Mirror Motor Synchronization - Power Folding 323

Exterior Mirrors - Exploded View
NOTE: LH side shown, RH side similar.

1 W705760 Exterior mirror nut (3 required)
2 17K707 Exterior mirror glass
3 - Exterior mirror motor screw (part of
17D696)
4 17D696 Exterior mirror motor
5 17D742 RH/ 17D743 Exterior mirror cover
LH
6 17682 RH/ 17683 LH Exterior mirror
2. For additional information on the mirror mounted puddle lamps and turn signals, refer to Section
417-01 .
Exterior Mirrors - Exploded View 324

Exterior Mirrors - Exploded View 325

Exterior Mirror
NOTE: If equipped with power folding mirrors, they must be synchronized any time the mirrors have been
folded or unfolded without using the mirror control switch. For additional information, refer to Exterior
Mirror Motor Synchronization - Power Folding in this section.
NOTE: Do not remove the exterior mirror assembly when repairing an individual part. Individual
components can be installed without removing the exterior mirror.
1. Remove the front door trim panel. For additional information, refer to Section 501-05 .
2. Position aside the weather shield.
3. Disconnect the exterior mirror electrical connector and pushpins.
4. Remove the exterior mirror.

Remove the nuts.

Install top nut first.
If equipped with power folding mirrors, they must be synchronized. For additional
information, refer to Exterior Mirror Motor Synchronization - Power Folding in this section.
Exterior Mirror 326

Exterior Mirror Glass
NOTICE: Failure to correctly remove the exterior mirror glass may result in exterior mirror motor
damage.
1. Position the exterior mirror glass to the full upward and inboard position and insert a thin flat-blade
screwdriver.
2. WARNING: Place a shop towel between the hands and the exterior mirror glass for
protection in case of glass breakage during mirror service. Failure to follow this instruction may
NOTE: LH mirror and motor shown removed from the housing and from the back to show location
of clips and placement of screwdriver.
Using a then flat-blade screwdriver, release the tabs starting at the lower outboard side of the exterior
mirror and continue to the lower inboard side. Remove the exterior mirror glass.
3. Disconnect the electrical connectors and remove the glass.

Rotate the exterior mirror glass in all directions after the stallation to make sure all clips are
completely attached.
Exterior Mirror Glass 327

Exterior Mirror Glass 328

Exterior Mirror Motor
1. Remove the mirror glass. For additional information, refer to Exterior Mirror Glass in this section.
2. Remove the 3 exterior mirror motor screws and exterior mirror motor.

Exterior Mirror Motor 329

Exterior Mirror Cover
1. Remove the mirror glass. For additional information, refer to Exterior Mirror Glass in this section.
2. Release the 4 retaining tabs and remove the exterior mirror cover.

Exterior Mirror Cover 330

Exterior Mirror Control Switch

1 17B676 Exterior mirror control switch
1. Remove the driver front door trim panel. For additional information, refer to Section 501-05 .
2. Remove the exterior mirror control switch.

1. Depress the locking tabs.
2. Remove the exterior mirror control switch.
Exterior Mirror Control Switch 331

Exterior Mirror Control Switch 332

Interior Rear View Mirror
Special Tool(s)
Installer, Rear View Mirror

501-025 (T94P-17700-AH)
Mirror Remover
501-D118A
Installer, Rear View Mirror

501-191
Mirror Remover
501-190
Mirror Identification

1 - Mirror type 1
2 - Mirror type 2
3 - Mirror type 3
4 - Mirror type 4
Removal
Interior Rear View Mirror 333

Mirror Type 1
NOTICE: The windshield must be at room temperature. Otherwise, damage to the windshield glass
may occur.
NOTE: Click here to view a video version of this procedure.
1. If equipped.
2.
3. NOTICE: Make sure the Mirror Remover is fully insertthe interior rear view mirror mount
access hole. Otherwise, damage to the windshield glass may occur.
Mirror Identification 334

4. Using a closed hand, bump the adjustment handle of the Mirror Remover to slide the mirror upward
on the mirror mount.
5.
Mirror Type 2
6.
Mirror Type 3
7.

8.
9.
Mirror Type 4
10.

11.
12. NOTICE: To prevent damage to the mirror or base, rotate the mirror base with hands only do
not use tools.
NOTICE: To prevent damage to the mirror wiring, do not rotate the mirror head beyond 180
degrees.
Installation
Mirror Type 1
NOTE: Click here to view a video version of this procedure.

1. Slide the interior rear view mirror mount over the windshield bracket from the top.
2. NOTE: An audible click will be heard as the mirror fully seats.
3. If equipped.

4. If equipped with compass module, check the compass zone and calibration. Refer to General
Procedures in Section 413-01 or Section 419-11.
Mirror Type 2
5.
6. If equipped with a compass module which requires calibration, check the compass zone adjustment
and calibration. Refer to General Procedures in Section 413-01 or Section 419-11.
Mirror Type 3
Mirror Type 4

If a new mirror has been installed, download the IPM-A configuration information from the
scan tool to the new IPM-A .
If a new mirror has been installed, perform camera alignment using a scan tool.


SECTION 501-10: Seating 2011 Expedition, Navigator Workshop Manual


Front Row
Backrest frame-to-seat track bolts 45 33 -
Cushion frame-to-seat track bolts 25 18 -
Lumbar screws 7 - 62
Safety belt buckle pretensioner nut 55 41 -
Seat-to-floor bolts a - - -
Seat track rail-to-seat track nuts (manual seat track) 30 22 -
Side air bag module nuts 10 - 89
Second Row - 20 Percent
Backrest-to-cushion bolts 48 35 -
Pivot bolt 55 41 -
Riser-to-cushion frame bolts 30 22 -
Safety belt buckle nut 55 41 Safety belt retractor anchor bolt 55 41 -
Safety belt retractor bolt 40 30 -
Seat-to-floor bolts a - - -
Swivel bolts 30 22 -
Second Row - 40 Percent E-Z Entry
Armrest bolt 45 33 -
Backrest-to-cushion bolts 55 41 -
Safety belt buckle bolt 50 37 -
Seat-to-floor bolts 40 30 -
Striker plate bolts 40 30 -
Third Row
Child safety seat tether anchor bolt 15 133
Inboard latch-to-backrest frame bolts, 40 percent 40 30 -
Inboard latch-to-backrest frame bolts, 60 percent 55 41 -
Inboard slide bracket-to-backrest frame nut 15 - 133
Inboard slide bracket-to-cushion frame nut 15 - 133
Inboard slide bracket-to-inboard latch nut 15 - 133
Outboard latch-to-cushion frame bolt, 60 percent seat 35 26 -
Outboard latch-to-cushion frame bolt, 40 percent seat 30 22 -
Outboard slide bracket-to-backrest frame nut 15 - 133
Outboard slide bracket-to-cushion frame nut 15 - 133
Outboard utboard latch nut 15 - 133
Power-fold seat motor bracket-to-latch bolt 30 22 -
Power-fold seat motor bracket-to-pivot bolt 30 22 -

Riser-to-cushion frame bolts 30 22 -

Safety belt anchor bolt 40 30 -
Safety belt buckle bolt 40 30 -
Seat-to-floor bolts 40 30 -
a Refer to procedure in this section.


Seats
Front Seats
The front seats can be equipped with the following serviceable components:
Adjustable head restraint and guide sleeves attached to the backrest frame
Backrest and cushion foam pads
Backrest and cushion covers
Backrest frames equipped with manual and power recliners (serviced with backrest frame only)
attached to the seat track
Seat cushion frames attached to the seat tracks
Manual adjustable lumbar assembly attached to the backrest and cushion frames
Power adjustable lumbar assembly attached to the backrest frame
Manual and power seat tracks located at the seat base
Memory system components attached to the driver seat
Climate controlled seat system components (heated/cooled seats)
Seat side air bag attached to the seat backrest frame
Safety belt buckle and pretensioner attached to the seat track
Cushion side shields attached to the outboard side of the seat cushion frames
Seat control switches attached to the cushion side shields
Seat track position sensor attached to driver seat track (part of the Supplemental Restraint System
(SRS))
Driver Seat Module (DSM) - Memory Seat
The driver power seat, power exterior mirrors, power adjustable pedals and adjustable steering column are
controlled by the Driver Seat Module (DSM) only when the vehicle is equipped with the programmable/recall
memory option. The DSM is located under the driver seat. To install a new DSM , refer to Driver Seat
Module (DSM) in this section. Programmable Module Installation (PMI) must be carried out when installing a
new DSM . Refer to Section 418-01 .
This system allows automatic positioning of the driver seat, power exterior mirrors, power adjustable pedals
and power tilt steering column to 2 programmable positions. The personalized memory seat positions are
recalled using memory switch buttons 1 and 2 or with the remote entry transmitter. Memory positions can be
stored at any time. A memory recall can be initiated only if the vehicle is in PARK or NEUTRAL and the
ignition switch is not in START. A memory recall in progress ill not be affected by moving the ignition
switch to START or by moving the gear selector lever out of PARK or NEUTRAL. For information on
programming memory positions or recalling stored memory position, refer to Memory Position Programming
in this section.
The memory seat system includes the following serviceable components:
DSM attached to the seat track

Memory SET switch attached to the cushion side shield
Adjustable pedal switch
Power mirror switch
Adjustable steering column switch
Memory seat track assembly (with seat position sensors integral to motors)
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Horizontal motor (part of seat track)
Front height motor (part of seat track)
Rear height motor (part of seat track)
Backrest power recliner motor (with integral position sensor) (part of backrest frame)
LH and RH memory power mirrors
Power adjustable memory pedals
Power adjustable steering column
Remote entry transmitter
Easy Entry/Exit
The easy entry/exit feature is a function of the DSM and can be enabled/disabled using a scan tool. When
enabled, the feature becomes a user accessible item on the message center allowing the user to turn the feature
on and off. Refer to the Owner's Literature or Section 413-01 for information on the message center.
Climate Controlled Seats
The climate control seat system is able to heat and cool the front seats. Each climate controlled seat is
operated by push-buttons on the HVAC module located on the instrument panel. Each front seat temperature
is then monitored and controlled by the Dual Climate Controlled Seat Module (DCSM) located on the
passenger front seat track.
The front seat cushions are equipped with a plenum (duct) attached to the cushion frame suspension wires
(serviced with the cushion frame). Conditioned air from the cushion Thermo-Electric Device (TED) and
blower assembly is routed through a plenum and into the manifold fitted within the cushion foam pad
(serviced with the cushion foam pad). The front seat backrest TED and blower assembly operates similarly by
routing conditioned air directly through the backrest manifold (serviced with the backrest foam pad).
The climate controlled seat system includes the following serviceable components:
HVAC module located in the instrument panel

DCSM attached to the passenger seat track
TED and blower assemblies attached to the backrest and cushion frames of each front seat
Air filter attached to each TED and blower assembly (See the Owner's Literature for additional
service and scheduled maintenance interval information)
Seat cushion and backrest foam pads equipped with manifolds (foam air ducts)
Ventilated seat cushion and backrest covers
Manual Lumbar
The manual front seat backrest lumbar is adjusted by a knob mounted on the side of the seat cushion side
shield. The lumbar adjuster is mounted to the seat track assembly and drives a cable connected to the lumbar
assembly attached to the backrest frame.
Power Lumbar
The driver seat has an electro-mechanical backrest lumbar assembly. The lumbar switch adjustment is on the
side of the seat cushion side shield and is part of the seat control switch. The lumbar motor is mounted to the
lumbar assembly and is serviced only with a new lumbar assembly.
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Manual Recliner
The manual recliner can be adjusted by a handle mounted on the outboard side of the cushion side shield.
Manual recliners are only serviceable by installing a new backrest frame assembly.
Power Recliner
The driver seat has an electro-mechanical backrest adjuster. The backrest adjustment switch is located on the
side of the seat cushion side shield and is part of the seat control switch. The recliner motor is mounted to the
backrest frame. Power recliners and motors are only serviceable by installing a new backrest frame assembly.
Seat Side Air Bags
The driver and passenger seat side air bags are attached to the seat backrest frame. If a seat side air bag
deployment has occurred, refer to Section 501-20B .
Safety Belt Buckle Pretensioners
The driver and passenger front seats are equipped with safety belt buckle and pretensioner assemblies attached
to the seat tracks. If a deployment has occurred, refer to Section 501-20B .
Second Row Seats
The second row is equipped with outboard 40 percent seats and can also be equipped with a center console or
center 20 percent seat.
40 Percent E-Z Entry Seats
The 40 percent E-Z entry seats are equipped with the following features:
Adjustable folding head restraints

Fold-flat backrests
Optional heated seat system
Kneeling seat base mechanisms for added level cargo area
Manual recliners
Tip-forward seat base mechanisms for easy entry to third row seating
The 40 percent E-Z entry seat is serviced as an assembly. Only the following components are serviceable:
All trim coverings

Adjustable head restraint and guide sleeves attached to the backrest frame
Armrest (if equipped)
Heated seat system components (if equipped)
Safety belt buckle
Seat mounting fasteners
Seat mounting striker plates
Seats 345
20 Percent Seat
The second row 20 percent center seat is equipped with the following serviceable items:
All trim covers

Backrest and cushion frames
Release handle and bezel attached to the backrest frame
Seat track attached to the seat base
Safety belt buckle attached to the seat track
Safety belt retractor attached to the seat backrest frame
Heated Seats
This system allows independent seat electrical heating of the outboard 40 percent seats on demand.
The rear heated seat system includes the following serviceable components:
Heater mats attached to the seat backrest and cushion foam pads
Heated seat module attached under the front floor console
Heated seat switches attached behind the floor console rear panel
Wiring harness attached to the seat cushion frame
Third Row Seats
The third row seats are a 60/40 percent folding split bench design with optional power-fold system option.
The third row seat includes the following serviceable items:
All trim covers

Backrest and cushion frames
Release handle and bezel attached to the backrest frame
Seat track attached to the seat base
Safety belt buckles attached to the seat track
Center safety belt retractor attached to the 60 percent seat backrest frame
Third Row Power-Fold Seat
The third row power-fold seats are activated by the rear power-fold seat switches. The power-fold seats only
operate with the vehicle in PARK, and the liftgate glass, liftgate door or any entry door is open, allowing the
SJB to enable power to the third row power-fold seat system.
The third row power-fold seat system includes the following serviceable components:
SJB located behind the instrument panel

RH and LH third row power-fold seat relays located behind the RH rear quarter trim panel
Seats 346
RH and LH power-fold seat motors attached to the base of the seat
RH and LH rear third row seat switches attached to the RH rear quarter trim panel
RH and LH drive gear assemblies attached to the base of the seat
The third row power-fold seat motors control drive gear assemblies to raise and lower the seat backrests. The
power-fold motors are serviceable separately.
Seats 347

Seats
Special Tool(s)
Flex Probe Kit



Medium Speed Controller Area Network (MS-CAN)
This vehicle utilizes a communication system called a Medium Speed Controller Area Network (MS-CAN).
When diagnosing the memory seat, climate controlled seat or third row power fold seat, use a Vehicle
Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware,
or equivalent scan tool with the latest software update with the capability of communicating over the
MS-CAN communication bus.
Driver and Passenger Power Seats Without Memory
The 10-way seat control feature moves the seat in 10 possible directions: the seat can be moved forward or
backward and the front and back of the cushion can be moved up and down independently. The backrest of
the seat can be moved forward and backward, and the lumbar can be moved in and out. All 10 positions are
controlled by one switch. The power seat feature operates independent of the ignition position.
The 6-way power seat feature moves the seat in 6 possible directions: the seat can be moved forward or
backward and the front and back of the cushion can be moved up and down independently. The power seat
feature operates independent of the ignition position.
The power seat motors are hardwired to the seat control switch. The circuits are normally at ground through
the seat control switch. An individual circuit is switched to voltage when a specific adjustment position is
selected.
Power Driver Seat With Memory
NOTE: Verify good battery condition before diagnosing the memory seat system. Poor battery condition may
interfere with memory seat operation, even if vehicle starting is possible.
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NOTE: A memory recall in progress does not prohibit the initiation of another memory recall; the most
recently requested memory recall will be executed.
The memory driver seat feature allows the driver to program a personalized seat position that can be recalled
using the memory switch or a Remote Keyless Entry (RKE) transmitter (if associated). There are 2 memory
settings possible. The power exterior mirrors, power adjustable pedal (if equipped) and power steering column
(if equipped) positions are also stored and recalled with the power driver seat positions. The power steering
column memory positioning is only used to raise the column upon easy exit and position it back upon easy
entry.
The Driver Seat Module (DSM) does not require calibration to the driver seat track, although soft stops must
be set within the seat track physical limits.
The driver seat control switch provides voltage to the DSM when activated. The neutral position of each
driver seat control switch position is a ground state through the seat control switch contacts. A voltage input
causes the DSM to power the appropriate motor until the input is removed. Ground is the normal state of the
motor circuits through the DSM and is not switched to control the motors. The DSM internally switches the
appropriate circuit from ground to voltage for operating the motors.
As the seat is adjusted, the DSM constantly monitors the motor position sensors to record the current seat
position. The DSM will remove voltage from the motor upon termination of the seat control switch input or if
the DSM does not see movement from the motor by monitoring the position sensor.
The DSM communicates DTCs and other information using the MS-CAN communication bus. It should be
noted for diagnostics that because Controller Area Network (CAN) bus communication is more robust and
reliable than other methods, it may be possible to have limited module communication with one of the CAN
bus circuits disconnected or shorted to ground. Refer to Section 418-00 for information concerning MS-CAN
bus communication.
This section only diagnoses concerns specific to the memory seat. To diagnose an exterior mirror concern,
refer to Section 501-09 . To diagnose a power adjustable pedal concern, refer to Section 206-06 . To diagnose
a power steering column concern, refer to Section 211-04 .
For information on programming memory positions or recalling a stored memory position, refer to Memory
Position Programming in this section.
Easy Entry/Exit Feature
The easy entry/exit feature is a function of the DSM that moves the driver seat backwards about 51 mm (2 in)
and the power steering column (if equipped) to the full upward position when the ignition key is removed
from the ignition switch. The DSM receives a key out command over the MS-CAN and powers the driver seat
rearward and the steering column upward. This function will not operate if the seat is less than the 51 mm (2
in) travel distance to the end of the track or the function has been disabled. The DSM will also cancel this
operation if a valid input command is received from the driver seat control switch, memory SET switch,
adjustable pedal control switch, exterior mirror control switch or power steering column switch.
The DSM will record the current seat and power steering column (if equipped) positions before powering the
seat and column for an easy exit operation. This recorded position will be used to return the seat and steering
column to this position on the easy entry operation. During easy entry operation, the seat and steering column
are returned to the position previous to the easy exit operation. Easy entry operation will be cancelled if a
valid input command is received by the DSM .
The easy entry/exit feature can be enabled/disabled using a scan tool. When enabled, the feature becomes a
Seats 349
user accessible item on the message center allowing the user to turn the feature on and off. Refer to the
Owner's Literature or Section 413-01 for information on the message center.
Remote Keyless Entry (RKE) Transmitter
NOTE: A memory recall in progress does not prohibit the initiation of another memory recall; the most
recently requested memory recall will be executed.
A Remote Keyless Entry (RKE) transmitter can be used to recall previously set memory positions but must
first be associated to that memory position. The transmitter associated with personality 1 is capable of
recalling memory position 1 only. Similarly, the associated personality 2 transmitter can recall only memory
position 2.
Memory recall occurs when the unlock switch is depressed on the RKE transmitter if it has been associated
with a memory position. The second depression of the unlock switch, which unlocks passenger doors, does
not initiate a memory recall.
For information on diagnosing an RKE concern or associating a RKE transmitter to a memory position, refer
to Section 501-14 .
Driver Seat Module (DSM) Hard Stop/Soft Stop
A hard stop occurs when one of the memory seat track, backrest (recline) or power steering column axes
physically reach the end of travel and can go no further. A soft stop occurs when the seat or steering column
stops before physically reaching the end of travel. The hard stop is set by seat or steering column design and
cannot be changed or adjusted. The soft stop is set by the DSM . The seat track axes are forward/rearward,
front up/down and rear up/down. The seat backrest axis is forward/rearward and the steering column axis is
up/down. To prevent unnecessary stress on the seat, steering column and motors, the DSM will set up to 10
soft stop positions, 2 for each moving axis. The DSM will use a preset distance from the hard stop to
determine where the soft stop will occur. When an axis reaches the hard stop and the switch is held for
approximately one second it will then back up 180 milliseconds and establish the soft stop for that axis in that
direction. The DSM uses this "back up" strategy to check sensor integrity any time movement has stopped
prematurely due to a sensor failure or obstruction.
Setting the Soft Stop
NOTE: If a new DSM has been installed, all power driver seat and power steering column (if equipped) soft
stops must be reset. If a new seat track, recline motor or power column has been installed, only reset the soft
stops for that component being installed new.
Use the following procedure once a new seat track, recline motor, power steering column or DSM has been
installed.
During the setting procedure, one second after a seat track, seat backrest or steering column axis reaches its
end of travel in either direction, the DSM will move the motor being used on that particular axis a small
amount in the opposite direction of the way the switch is being pressed. Once the motor has moved the seat
track or backrest this small amount, the soft stop is set and the switch can be released.
1. Turn the ignition key to the ON position.
2. Press the seat control switch horizontal button forward until the seat track stops.
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3. Keep the horizontal button pressed forward for one second after the seat track reaches its forward end
of travel. The seat track will then move back a small amount. The horizontal forward soft stop has
been set, release the switch button.
4. Repeat Steps 2 and 3 for all seat track and backrest axes in both directions.
5. Repeat Steps 2 and 3 for power column (if equipped).
Climate Controlled Seat System
NOTICE: Avoid applying voltage directly to a Thermo-Electric Device (TED) for testing its operation.
Doing so may cause damage to the TED .
NOTE: When installing a new Dual Climate Controlled Seat Module (DCSM), it is necessary to carry out
Programmable Module Installation (PMI). Refer to Section 418-01 .
Both the driver and front passenger climate controlled seats are independently controlled electronically by the
DCSM mounted to the bottom of the passenger seat cushion. The climate controlled seat system only operates
with the engine running, however, if using a scan tool to command the DCSM , diagnostic testing can be
carried out with the ignition ON engine OFF in 15 second durations. The system receives voltage from
Battery Junction Box (BJB) fuse 67 (40A) supplying battery voltage into the DCSM .
If one of the voltage supply circuits opens, both seats will remain operational because the circuits are
connected internally in the DCSM .
Both climate controlled seats operate independently. If a fault occurs setting a DTC specific to either climate
controlled seat, only the affected seat will be disabled by the module. If the system shuts down due to a DTC
fault, cycling the ignition to OFF and then ON again will reset the DCSM to function until the DTC resets.
The 4 climate controlled seat switches (identified with seat icons) on the HVAC module activate each seat
system setting and illuminate indicators above each switch to indicate the operating mode. There are 3
indicators for HIGH, 2 indicators for MED and 1 indicator for LOW.
Each driver and front passenger seat cushion and backrest is equipped with a Thermo-Electric Device (TED)
and blower motor assembly. Applying voltage polarity to the TED in one direction, causes it to heat.
Applying voltage polarity in the opposite direction causes the TED to cool. Cabin air is drawn through the
blower and distributed to each of the TED modules located in the seat cushion and backrest. The TEDs then
heat or cool the incoming air depending on the control switch settings. The air is then directed into the foam
pad and manifold where it is distributed along the surface of the cushion and backrest of the seat. Once
activated, the DCSM maintains the heating/cooling modes until deactivated.
The temperature differences between the individual heated and cooled settings is minimal. For example, it is
difficult to distinguish between LOW cool and MED cool settings. Measuring seat temperature at different
settings is possible by monitoring the DCSM PIDs using the scan tool.
The HVAC module communicates climate controlled seat commands to the DCSM using the MS-CAN bus.
The MS-CAN bus is connected to the Data Link Connector (DLC) for diagnostic use. No direct connection
exists between the DCSM and HVAC module for the climate controlled seat switches. The climate controlled
seats can be commanded on or off using the scan tool to verify both module communication on the MS-CAN
bus and operation of the DCSM . This method may be useful for isolating a control switch concern. It should
also be noted that because CAN bus communication is more robust and reliable than other methods, it may be
possible to have limited module communication with one of the CAN bus circuits disconnected or shorted to
ground. Refer to Section 418-00 for information concerning CAN bus communication.
Seats 351
Heating Characteristics
In heat mode, the TED circuits of a given seat are wired in parallel internally in the DCSM .
The climate controlled seat system draws approximately 24 amperes, with both seats heating, until
reaching the set point and then the system operates at a reduced amperage to maintain the climate
setting.
In heat mode, the TED can add up to 40C-60C (72F-108F) to the ambient inlet air temperature as
it passes over the TED .
The system control settings are based on the indicators above each climate controlled seat heat switch
button on the HVAC module.
In the LOW setting, the DCSM is set to maintain TED temperature at approximately 46C (115F).
In the HIGH setting, the DCSM is set to maintain TED temperature at 65C (149F).
When heating, the DCSM will vary the speed of the fans and the TED duty cycle in order to reach and
maintain the temperature determined by the switch setting (closed loop operation). Refer to the
following table for heating mode temperatures.
Heating Mode Initial Temperature Final Temperature

HIGH 90C (194F) 65C (149F)
MED 80C (176F) 60C (140F)
LOW 75C (167F) 46C (115F)
Cooling Characteristics
In cool mode, the TED circuits are wired in series internally in the DCSM .
The climate controlled seat system draws approximately 7 amps.
In cool mode, the TED can remove up to 8C (14F) from the ambient air temperature entering the
system.
The system control settings are based on the indicators above each climate controlled seat cool switch
button on the HVAC module.
When cooling, the DCSM maintains constant speed of the fans and constant TED supply voltage
(duty cycle) in open loop COOL mode (refer to the following table).
Cooling Mode TED Voltage TED Supply Duty Cycle

HIGH Vbat 100%
MED Vbat 75%
LOW Vbat 50%
The climate controlled seat system is deactivated by one of the following actions:
Selecting the HVAC module setting to manual OFF

Turning the vehicle OFF
If the temperature at one of the TEDs falls below 5C (41F), the DCSM will shut down the TEDs and initiate
system recovery mode. If the temperature continues to drop below 2C (36F), the DCSM will shut down the
fans in the affected seat.
Seats 352
Climate Controlled Seat System Recovery Mode
NOTE: The presence of overtemperature faults (DTCs B2729, B2730, B272A and B272B) can be induced by
incorrect operation of the climate controlled seat system after an initial heat setting has been attained. If a heat
setting is repeatedly turned OFF and ON in an attempt to increase the seat temperature or repeatedly toggled
between heat and cool modes, an overtemperature condition can result and the DTC(s) will be set.
If the temperature at one of the TEDs rises above 110C (230F) in the heat mode or 65C (149F) in the cool
mode for more than 4 seconds, the DCSM will record an overtemperature DTC, remove voltage from the
TEDs and go into recovery mode (blower only) for 30 seconds to cool down the TEDs . The same will occur
if a temperature difference of 60C (108F) or greater is seen between the backrest and cushion TEDs on
either front seat. The DCSM will continue to monitor the TEDs while in recovery mode. If the temperature of
the TEDs does not drop to 105C (221F) in the heat mode or 60C (140F) in the cool mode after 30
seconds, the system will continue to cool the TEDs in recovery mode for up to 5 minutes. If the TEDs cool
down at anytime after 30 seconds, but before 5 minutes (checked at 4-second intervals), the system will
operate as normal. An overtemperature DTC will still be recorded even if the recovers and is operating
normally. This scenario is more likely to occur during extreme cabin temperatures with significant seat back
sunload. If the system does not recover within 30 seconds in heat mode or within 5 minutes in cool mode, the
DCSM will disable that seat (fault mode) and remain off until the ignition is cycled. Also, if the DCSM
detects temperature differential fault twice during the same ignition cycle, it will shutdown. When a fault
causes a shutdown the climate controlled seat indicators will turn off and that seat will not be operational until
the next key cycle.
Heated Seats - Rear
Vehicles equipped with rear heated seats are equipped with a single-heated seat module to control both rear
heated seats. The heated seat module is located under the front floor console. When the heated seat switch is
pressed, a momentary ground signal is sent to the heated seat module. The heated seat module then supplies
voltage to the heater circuit. The seat cushion and backrest heater mats are wired in series and supplied
voltage by the same output. The heated seat module monitors inputs from a temperature sensor, located in
each seat's cushion heater mat and maintains seat temperature by cycling the heater feed output as necessary
to maintain the set point temperature. The heated seat module will send voltage to the indicator circuit at the
heated seat switch to indicate an on state. The heated seat module will remain on until the heated seat switch
is pressed to supply a second momentary ground signal or the ignition is set to OFF. The heated seat module
does not time out.
The heated seat module does not report DTCs and does not communicate on any network. If a fault is detected
the affected seat system will be disabled. The faults detected will be:
a heater feed circuit short to battery, ground or open.

sensor circuit short to battery or open.
heated seat switch stuck closed to ground.
heated seat switch low and high inputs shorted together.
To reset the module, cycle the ignition OFF and then ON. After the heated seat module has been reset, the
module will return to an off state. The heated seat module does not report DTCs and does not communicate on
any communication network.
A new heated seat module must be configured after installation for correct operation. Heated seat module
configuration occurs automatically when the low heat mode button is pressed on either rear heated seat
switch. Until the module is correctly configured, the heated seats will operate incorrectly from the high heat
de button on either heated seat switch by following a sequence of high, low and off with each button press.
After the low heat mode button is pressed on either heated seat switch, the module will correctly configure
Seats 353
and the system will operate correctly.
Third Row Power-Fold Seat
NOTICE: To prevent possible damage to the third row seat or the safety belts, make sure that the safety
belts are not fastened when moving the seat to the load floor position.
NOTICE: Make sure that no objects such as books, purses or briefcases are on the floor in front of the
third row seats or on the seat cushion before lowering the backrest(s). Failure to follow this instruction
may cause incorrect operation of the seat.
For the third row power-fold seat to operate, voltage is supplied by the SJB to the power-fold seat relay,
enabling the seats to then be moved by pressing the third row power-fold seat switches. The third row
power-fold seat operates only when the vehicle is in PARK and the liftgate glass, liftgate door or any entry
door must be open.
The third row power-fold seat motors transfer movement to a drive gear assembly to raise and lower the seat
backrest. The power-fold seat motors rotate a short torque shaft which is connected to the drive gear
assembly. The power-fold seat motor and bracket assembly is serviceable separately. Refer to Power-Fold
Seat Motor in this section.
1. Verify the customer concern by operating the power seat, memory seat or climate controlled seat
functions.
2. Visually inspect for obvious signs of mechanical and electrical damage.
Switch(es) Battery Junction Box (BJB) fuse(s):

Seat tracks obstructed or damaged 22 (30A) (passenger seat control
Lumbar assembly damaged switch)
Recliner assembly damaged (backrest frame) 67 (40A) (Dual Climate Controlled
Thermo-Electric Device (TED) assembly Seat Module (DCSM))
filter dirty (cushion or backrest) 70 (40A) (LH and RH third row
power-fold seat)
74 (30A) (driver seat control switch
or Driver Seat Module (DSM) output)
Smart Junction Box (SJB) fuse(s):
2 (15A) ( DSM logic)
5 (10A) (third row power-fold seats
relay enable)
12 (7.5A) (memory seat control
switch)
Seats 354
18 (20A) (second row heated seat

module output)
35 (10A) (second row heated seat
module logic)
Wiring harness
Loose or corroded connector(s)
Seat control switch
Lumbar control switch
Memory SET switch
Power seat motor (seat track)
Power lumbar motor (lumbar assembly)
TED assembly (cushion or backrest)
Power recliner motor (backrest frame)
Third row power-fold seat relay(s)
DSM
DCSM
HVAC module
Second row seat cushion heater mat
Second row seat backrest heater mat
Second row heated seat module
4. If the concern is with the power seat (non-memory seat) or the power lumbar and the cause is not
visually evident, verify the symptom and GO to Symptom Chart .
5. If the concern is with the memory seat or climate controlled seat and the cause is not visually evident,
connect the scan tool to the Data Link Connector (DLC).
6. NOTE: The Vehicle Communication Module (VCM) LED prove out confirms voltage and ground


refer to Section 418-00 to diagnose no response from the PCM.

418-00 .
If the network test passes, retrieve and record on-demand and Continuous Memory
Diagnostic Trouble Codes (CMDTCs).
9. Clear the CMDTCs and carry out the self-test diagnostics for the DSM or DCSM .
Seats 355
10. If the DTCs retrieved are related to the concern, go to Driver Seat Module (DSM) DTC Chart, Smart
Junction Box (SJB) DTC Chart or Dual Climate Controlled Seat Module (DCSM) DTC Chart. For all
other DTCs, refer to Section 419-10 .
DTC Charts

B106E Solid State Driver Disabled GO to Pinpoint Test BC .
Due to Short Circuit
B106F Module Disabled Due to GO to Pinpoint Test BC .
External Fault
B112B Mirror Power Fold Switch REFER to Section 501-09 .
Input Short to Battery
B1317 Battery Voltage High GO to Pinpoint Test AY .
B1318 Battery Voltage Low GO to Pinpoint Test AZ .
B1342 ECU Is Faulted CLEAR the DTCs. REPEAT the self-test. If DTC B1342 is retrieved
again, INSTALL a new Driver Seat Module (DSM). REFER to Driver
Seat Module (DSM) in this section. TEST the system for normal
operation.
B1530 Memory Set Switch Circuit REFER to Section 501-10 .
Short to Ground
B1534 Memory 1 Switch Circuit GO to Pinpoint Test M .
Short to Ground
B1538 Memory 2 Switch Circuit GO to Pinpoint Test M .
Short to Ground
B1663 Seat Driver Front Up/Down If the motor does not operate, GO to Pinpoint Test L . If motor operates,
Motor Stalled GO to Pinpoint Test M .
B1664 Seat Driver Rear Up/Down If the motor does not operate, GO to Pinpoint Test L . If motor operates,
Motor Stalled GO to Pinpoint Test M .
B1665 Seat Driver If the motor does not operate, GO to Pinpoint Test L . If motor operates,
Forward/Backward Motor GO to Pinpoint Test M .
Stalled
B1666 Seat Driver Recline Motor If the motor does not operate, GO to Pinpoint Test L . If motor operates,
Stalled GO to Pinpoint Test M .
B1667 Mirror Driver Up/Down REFER to Section 501-09 .
Motor Stalled
B1668 Mirror Driver Right/Left REFER to Section 501-09 .
Motor Stalled
B1669 Mirror Passenger Up/Down REFER to Section 501-09 .
Motor Stalled
B1670 Mirror Passenger REFER to Section 501-09 .
Right/Left Motor Stalled
B1703 Seat Driver Recline GO to Pinpoint Test L .
Forward Switch Circuit
Seats 356
Short to Battery
B1707 Seat Driver Recline GO to Pinpoint Test L .
Rearward Switch Circuit
Short to Battery
B1711 Seat Driver Front Up GO to Pinpoint Test L .
Switch Circuit Short to
Battery
B1715 Seat Driver Front Down GO to Pinpoint Test L .
Battery
B1719 Seat Driver Forward Switch GO to Pinpoint Test L .
Circuit Short to Battery
B1723 Seat Driver Rearward GO to Pinpoint Test L .
Battery
B1727 Seat Driver Rear Up Switch GO to Pinpoint Test L .
B1731 Seat Driver Rear Down GO to Pinpoint Test L .
Battery
B1733 Mirror Driver Vertical REFER to Section 501-09 .
Switch Circuit Failure
B1737 Mirror Driver Horizontal REFER to Section 501-09 .
B1741 Mirror Passenger Vertical REFER to Section 501-09 .
Horizontal Switch Circuit
Failure
B1952 Seat Rear Up/Down GO to Pinpoint Test M .
Position Feedback Circuit
Short to Battery
B1953 Seat Rear Up/Down GO to Pinpoint Test M .
Short to Ground
B1956 Seat Front Up/Down GO to Pinpoint Test M .
Short to Battery
B1957 Seat Front Up/Down GO to Pinpoint Test M .
Short to Ground
B1960 Seat Recline GO to Pinpoint Test M .
Forward/Backward Position
Feedback Circuit Short to
Battery
B1961 Seat Recline GO to Pinpoint Test M .
Forward/Backward Position
Ground
B1964 GO to Pinpoint Test M .
Seats 357
Seat Horizontal
Forward/Rearward Position
Battery
B1965 Seat Horizontal GO to Pinpoint Test M .
Forward/Rearward Position
Ground
B1987 Pedal Forward/Rearward REFER to Section 206-00 .
Motor Stalled
B1988 Pedal Position Forward REFER to Section 206-00 .
Battery
B1989 Pedal Position Rearward REFER to Section 206-00 .
Battery
Feedback Potentiometer
B2084 Memory Set Indicator Short NOTE: The memory set indicator application is not used for this
to Ground vehicle and is disabled by default in all modules. The presence of this
DTC indicates module software error.
DISCONNECT and CHECK DSM C341D for damaged or shorted pins.

REPAIR as necessary. CLEAR the DTCs. REPEAT the self-test. If
DTC B2084 is retrieved again, INSTALL a new DSM . REFER to
Driver Seat Module (DSM) in this section.
B2223 Mirror Driver Drive Circuit REFER to Section 501-09 .
Failure
B2224 Mirror Passenger Drive REFER to Section 501-09 .
Circuit Failure
Pot. Feedback Ckt. Short to
GND
Horizontal Feedback
Potentiometer Circuit
Failure
Horizontal Feedback
Potentiometer Circuit Short
to Battery
Circuit Failure
Circuit Failure
Seats 358

Circuit Failure
B2330 Column Reach Feedback REFER to Section 211-00 .
to Battery
B2331 Column Reach Feedback REFER to Section 211-00 .
to Ground
B2334 Column Tilt Feedback REFER to Section 211-00 .
to Battery
B2335 Column Tilt Feedback REFER to Section 211-00 .
to Ground
B2340 Column Reach Motor REFER to Section 211-00 .
Stalled
B2341 Column Tilt Motor Stalled REFER to Section 211-00 .
B2477 Module Configuration REFER to Section 418-01 .
Failure
B2A41 Steering Column REFER to Section 211-00 .
Telescopic Rear Switch
Short to Battery
B2A42 Steering Column Tilt Up REFER to Section 211-00 .
Switch Short to Battery
B2A44 Steering Column REFER to Section 211-00 .
Telescopic Forward Switch
Short to Battery
U0140 Lost Communication With GO to Pinpoint Test BA .
Body Control Module
(GEM)
U0155 Lost Communication With GO to Pinpoint Test BB .
Instrument Panel Cluster
(IC) Control Module
U2050 No Application Present REFER to Section 418-01 .
Dual Climate Controlled Seat Module (DCSM) DTC Chart

B103B GO to Pinpoint Test AB .
Seats 359
Thermoelectric Driver
Overcurrent Low
B103C Thermoelectric Driver Open GO to Pinpoint Test AC .
Load
B103D Blower Driver Overtemperature GO to Pinpoint Test AD .
B1111 Driver Thermoelectric Device GO to Pinpoint Test AB .
Control Overtemperature Fault
B1113 Passenger Thermoelectric GO to Pinpoint Test AE .
Device Control Overtemperature
Fault
B111B Passenger Thermoelectric Driver GO to Pinpoint Test AE .
Overcurrent Low
B111C Passenger Thermoelectric Driver GO to Pinpoint Test AF .
Open Load
B111D Passenger Blower Driver GO to Pinpoint Test AG .
Overtemperature
B1342 ECU is Faulted INSTALL a new Dual Climate Controlled Seat Module (DCSM).
REFER to Dual Climate Controlled Seat Module (DCSM) in this
section.
B19A1 Passenger Seat Cushion Blower GO to Pinpoint Test AH .
Speed Short to Battery
B19A2 Passenger Seat Back Blower GO to Pinpoint Test AI .
B19A3 Driver Seat Cushion Blower GO to Pinpoint Test AJ .
B19A4 Driver Seat Back Blower Speed GO to Pinpoint Test AK .
Short to Battery
B19A5 Passenger Seat Cushion Blower GO to Pinpoint Test AL .
Speed Short to Ground
B19A6 Passenger Seat Back Blower GO to Pinpoint Test AM .
B19A7 Driver Seat Cushion Blower GO to Pinpoint Test AN .
B19A8 Driver Seat Back Blower Speed GO to Pinpoint Test AO .
Short to Ground
B2477 Module Configuration Failure NOTE: This DTC indicates Programmable Module Installation
(PMI) has not been done to a newly installed module or
configuration data has been lost.
CARRY OUT PMI on the DCSM . REFER to Section 418-01 .

REPEAT the self-test. If PMI is successful, the DTC will not be
present.
B2486 Climate Control Seat Module GO to Pinpoint Test AP .
Voltage Out of Range
B2729 Cushion Over-Temp Detected GO to Pinpoint Test AQ .
(Driver)
B272A Passenger Cushion Over-Temp GO to Pinpoint Test AR .
Detected
B272B GO to Pinpoint Test AS .
Seats 360
Passenger Back Over-Temp

Detected
B272C Driver Differential Temperature GO to Pinpoint Test AT .
Fault
B272D Passenger Differential GO to Pinpoint Test AU .
Temperature Fault
B272E Driver Ignition Run/Blower GO to Pinpoint Test AV .
Circuit Short to Ground (this
DTC sets for an open or short to
voltage)
B272F Passenger Ignition Run/Blower GO to Pinpoint Test AW .
Circuit Short to Ground (this
DTC sets for an open or short to
voltage)
B2730 Back Over-Temp Detected GO to Pinpoint Test AX .
(Driver)
U2050 No Application Present INSTALL a new DCSM . REFER to Dual Climate Controlled
Seat Module (DCSM) in this section. REPEAT the self-test.
All - REFER to Section 419-10 .
Other
DTCs

B2794 Third Row Power Fold Circuit Failure GO to Pinpoint Test
Y.
B2A2D Third Row Power Fold Circuit Short to Ground GO to Pinpoint Test
Y.
All Other DTCs - REFER to Section
419-10 .
Symptom Chart
No communication with the Driver Seat Module (DSM)
Fuse
Circuitry
DSM
Seats 361
No communication with the Dual Climate Controlled Seat Module (DCSM)
Fuse
Circuitry
DCSM
No communication with the module - unable to carry out self-test wi the DSM
Fuse(s)
Circuitry
DSM
The power seat is inoperative - driver, with power recliner
Fuse
Circuitry
Seat control switch
GO to Pinpoint Test A .
The power seat is inoperative - driver, with manual recliner
Fuse
Seat control switch
Circuitry
GO to Pinpoint Test B .
The power seat is inoperative - passenger, with power recliner
Fuse
Circuitry
Seat control switch
GO to Pinpoint Test C .
The power seat is inoperative - passenger, with manual recliner
Fuse
Seat control switch
Circuitry
GO to Pinpoint Test D .
The power seat does not move horizontally/vertically/recline - driver, with power recliner
Seat track
Circuitry
Seat control switch
Power seat motor
Seats 362
GO to Pinpoint Test H .
The power seat does not move horizontally/vertically - driver, with manual recliner
Circuitry
Seat control switch
Power seat motor
GO to Pinpoint Test I .
The power seat does not move horizontally/vertically/recline - passenger, with power recliner
Seat track
Circuitry
Seat control switch
Power seat motor
GO to Pinpoint Test J .
The power seat does not move horizontally/vertically - passenger, with manual recliner
Circuitry
Seat track
Seat control switch
Power seat motor
GO to Pinpoint Test K .
The memory seat is inoperative/does not operate correctly - does not operate
horizontally/vertically/recline
Fuse
rcuitry
Seat control switch
Seat track
DSM
Power seat motor
GO to Pinpoint Test L .
The memory seat does not operate correctly - the seat moves in one second intervals
Circuitry
Seat track
DSM
REFER to the Driver Seat Module (DSM) DTC Chart in this section.
The memory seat does not operate correctly - does not operate using the memory SET switch
Circuitry
Memory SET switch
Seat track
Seats 363
DSM
GO to Pinpoint Test M .
The memory seat does not operate correctly - does not o using the Remote Keyless Entry (RKE)
transmitter
RKE transmitter is not correctly associated to a memory position

Circuitry
Keyless entry transmitter
DSM
Smart Junction Box (SJB)
VERIFY the RKE transmitter is operating correctly and is associated to a memory position. REFER
to Owner's Literature or Section 501-14 for information on associating a RKE transmitter. RUN the
DSM self-test and REFER to the Driver Seat Module (DSM) DTC Chart in this section to diagnose
any DTCs retrieved.
Easy exit/easy entry is inoperative/does not operating correctly
Circuitry
Key in ignition switch
DSM
GO to Pinpoint Test N .
The power lumbar is inoperative - driver
Circuitry
Seat control switch
Power lumbar assembly
GO to Pinpoint Test O .
The power lumbar is inoperative - passenger
Circuitry
Seat control switch
Power lumbar assembly
GO to Pinpoint Test P .
All climate controlled seats are inoperative
Fuse
Circuitry
Medium Speed Controller Area Network (MS-CAN) communication fault
DCSM
HVAC module
VERIFY BJB fuse 67 (40A) is OK. If not OK, REFER to the Wiring Diagrams manual to identify
possible causes of the circuit short. TEST the system for normal operation. If OK, CARRY OUT the
network test using a scan tool and VERIFY network communication of the HVAC module and
Seats 364
DCSM . REFER to Section 418-00 to diagnose a module communication or network concern. If OK,
CARRY OUT the DCSM self-test. If any DTC is present, REFER to the Dual Climate Controlled
Seat Module (DCSM) DTC Chart. CHECK the climate control system for correct operation. REFER
to Section 412-00 for diagnosis of the HVAC module or climate control system. If OK, INSTALL a
new DCSM . REFER to Dual Climate Controlled Seat Module (DCSM) in this section.
A single climate controlled seat is inoperative - switch indicators may or may not illuminate
Circuitry
HVAC module
DCSM
NOTE: If a fault occurs setting a DTC specific to only one climate controlled seat, the DCSM will
allow the other seat to remain operational. CHECK for DTCs specific to the affected climate
controlled seat and, if a DTC is present, REFER to the Dual Climate Controlled Seat Module (DCSM)
DTC Chart.
GO to Pinpoint Test Q .
A single climate controlled seat does not operate correctly - poor or intermittent cooling/heating
Excessive sunload or extreme cabin temperatures

Incorrectly installed Thermo-Electric Device (TED), manifold or plenum
Airflow blockage
TED
DCSM
Seat Module (DCSM) DTC Chart in this section. If no DTC is present, CHECK the affected seat
cushion or backrest for correct installation of the climate controlled seat components ( TED ,
manifold, plenum, air ducts and foam pad) and REPAIR as needed. If OK, CHECK for airflow
restrictions ( TED inlets and outlets, TED -to-manifold or plenum connections, filters and ducts) and
REPAIR as needed. CHECK the TED cooling performance on the affected seat and VERIFY the
system is operating correctly. REFER to Component Test - Thermo-Electric Device (TED) Cooling
Performance in this section. RETEST the system for normal operation.
A single climate controlled seat does not operate correctly - exhibits poor airflow or performance
Incorrectly installeTED , manifold or plenum

Airflow blockage
Disconnected air duct
Seat Module (DCSM) DTC Chart in this section. If no DTC is present, CHECK the affected seat
cushion or backrest for correct installation of the climate controlled seat components ( TED ,
manifold, plenum, air ducts and foam pad) and REPAIR as needed. If OK, CHECK for airflow
restrictions ( TED inlets and outlets, TED -to-manifold or plenum connections, filters and ducts) and
REPAIR as needed. RETEST the system for normal operation.
A second row E-Z entry seat does not operate correctly - seat stuck in E-Z entry position
Incorrect shipping pin position
CHECK the shipping pin at the seat pedestal pivot is in the released position. REFER to Seat - Second
Seats 365
Row, 40 Percent in this section.
The heated seats are inoperative - rear
Fuse
Circuitry
Heated seat module
GO to Pinpoint Test R .
The heated seat is inoperative - left rear
Fuse
Circuitry
Heated seat switch
Seat cushion heater mat
Seat backrest heater mat
Heated seat module
GO to Pinpoint Test S .
The heated seat is inoperative - right rear
Fuse
Circuitry
Heated seat switch
Seat cushion heater mat
Seat backrest heater mat
Heated seat module
GO to Pinpoint Test T
The heated seat does not operate correctly - left rear seat does heat but the heated seat indicator does
not illuminate when pressed

Heated seat switch
Heated seat module
GO to Pinpoint Test U .
The heated seat does not operate correctly - right rear seat does heat but the heated seat indicator does
not illuminate when pressed

Heated seat switch
Heated seat module
GO to Pinpoint Test V .
The heated seat does not operate correctly - left rear heated seat indicator is always on

Heated seat module
Seats 366
GO to Pinpoint Test W .
The heated seat does not operate correctly - right rear heated seat indicator is always on

Heated seat module
GO to Pinpoint Test X .
The heated seats do not operate correctly - after a new heated seat module is installed
Heated seat module configuration
OPERATE one heated seat using the low button to configure the module. REFER to Principles of
Operation in this subsection or Heated Seat Module - Second Row in this section.
The power seat is inoperative - third row power-fold, left and right seats
Fuse(s)
Circuitry
SJB
GO to Pinpoint Test Y .
The power seat is inoperative/does not operate correctly - third row power-fold, left seat
Fuse(s)
Circuitry
Power-fold seat relay
Seat control switch(es)
Power-fold seat motor
GO to Pinpoint Test Z .
The power seat is inoperative/does not operate correctly - third row power-fold, right seat
Fuse(s)
Circuitry
Power-fold seat relay
Seat control switch(es)
Power-fold seat motor
GO to Pinpoint Test AA .
Pinpoint Tests
NOTICE: Most faults are due to connector and/or wiring concerns. Carry out a thorough inspection
and verification before proceeding with the pinpoint test.
NOTICE: Use the correct probe adapter(s) from the Flex Probe Kit when taking measurements. Failure
to use the correct probe adapter(s) may damage the connector.
Seats 367
Pinpoint Test A: The Power Seat is Inoperative - Driver, With Power Recliner
Refer to Wiring Diagrams Cell 120 , Power Seats for schematic and connector information.
Normal Operation
The driver seat control switch is powered by battery voltage on circuit SBB74 (YE/RD) and is supplied
ground on circuit GD143 (BK/VT). When pressed, the seat control switch supplies that voltage and ground to
a power seat track motor or power recline motor to move the seat or backrest. When pressed in the opposite
direction, the seat control switch reverses the polarity to that same power seat track motor or power recline
motor, which moves the seat or backrest in the opposite direction. There are 3 power seat track motors that
combine to move the seat cushion horizontally (forward/rearward) and vertically (front up/down and rear
up/down). There is an additional motor in the power recline mechanism to move the seat backrest forward and
rearward. If a new seat track motor needs to be installed, it is necessary to install an entire power seat track.

Fuse
Seat control switch
PINPOINT TEST A: THE POWER SEAT IS INOPERATIVE - DRIVER, WITH POWER RECLINER
NOTE: The air bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is
removed and the ignition is ON.
NOTE: The Supplemental Restraint System (SRS) must be fully operational and free of faults before
releasing the vehicle to the customer.

A1 CHECK FOR VOLTAGE TO THE SEAT
CONTROL SWITCH
Yes
Depower the SRS . Refer to Supplemental Restraint
System (SRS) Depowering and Repowering in the No
General Procedures portion of Section 501-20B . VERIFY Battery Junction Box (BJB) fuse
Disconnect: Driver Seat Safety Belt Buckle 74 (30A) is OK. If OK, REPAIR the
Pretensioner C3049. circuit. If not OK, REFER to the Wiring
Disconnect: Driver Seat Side Air Bag C3051. Diagrams manual to identify possible
Disconnect: Driver Seat Control Switch C3016. causes of the circuit short. TEST the
WARNING: Make sure no one is in the vehicle system for normal operation.
and there is nothing blocking or placed in front of
any air bag module when the battery is DISCONNECT the battery ground cable.
connected. Failure to follow these instrtions may CONNECT driver safety belt buckle
result in serious personal injury in the event of an pretensioner C3049.
accidental deployment.
Connect the battery ground cable. Refer to Section CONNECT driver seat side air bag
414-01 . module C3051.
Measure the voltage between driver seat control
switch C3016-5, circuit SBB74 (YE/RD), harness REPOWER the SRS . REFER to Section
side and ground. 501-20B .


A2 CHECK THE SEAT CONTROL SWITCH
GROUND CIRCUIT FOR AN OPEN
Yes
Measure the resistance between driver seat control INSTALL a new driver seat control
switch C3016-3, circuit GD143 (BK/VT), harness switch. REFER to Seat Control Switch -
side and ground. Front in this section. TEST the system for
normal operation.
DISCONNECT the battery ground cable.

CONNECT driver safety belt buckle
pretensioner C3049.
CONNECT driver seat side air bag

module C3051.
REPOWER the SRS . REFER to Section

501-20B .
No
normal operation.

pretensioner C3049.

module C3051.

501-20B .
Pinpoint Test B: The Power Seat is Inoperative - Driver, With Manual Recliner
Normal Operation
a power seat track motor to move the seat. When pressed in the opposite direction, the seat control switch
reverses the polarity to that same power seat trk motor, which moves the seat in the opposite direction. There
are 3 power seat track motors that combine to move the seat cushion horizontally (forward/rearward) and
vertically (front up/down and rear up/down). If a new seat track motor needs to be installed, it is necessary to
install an entire power seat track.


Fuse
Seat control switch
PINPOINT TEST B: THE POWER SEAT IS INOPERATIVE - DRIVER, WITH MANUAL RECLINER

B1 CHECK FOR VOLTAGE TO THE SEAT CONTROL
SWITCH
Yes
Depower the SRS . Refer to Supplemental Restraint System
(SRS) Depowering and Repowering in the General No
Procedures portion of Section 501-20B . VERIFY Battery Junction Box
Disconnect: Driver Seat Safety Belt Buckle Pretensioner (BJB) fuse 74 (30A) is OK. If
C3049. OK, REPAIR the circuit. If not
Disconnect: Driver Seat Side Air Bag C3051. OK, REFER to the Wiring
Disconnect: Driver Se Control Switch C352. Diagrams manual to identify
WARNING: Make sure no one is in the vehicle and possible causes of the circuit
there is nothing blocking or placed in front of any air bag short. TEST the system for
module when the battery is connected. Failure to follow normal operation.
these instructions may result in serious personal injury in
the event of an accidental deployment. DISCONNECT the battery
Connect the battery ground cable. Refer to Section 414-01 . ground cable. CONNECT driver
Measure the voltage between driver seat control switch safety belt buckle pretensioner
C352-4, circuit SBB74 (YE/RD), harness side and ground. C3049.
CONNECT driver seat side air

bag module C3051.
REPOWER the SRS . REFER to

Section 501-20B .

B2 CHECK THE SEAT CONTROL SWITCH GROUND
CIRCUIT FOR AN OPEN
PINPOINT TEST B: THE POWER SEAT IS INOPERATIVE - DRIVER, WITH MANUAL RECLINER
370
Measure the resistance between driver seat control switch Yes

C352-2, circuit GD143 (BK/VT), harness side and ground. INSTALL a new driver seat
control switch. REFER to Seat
Control Switch - Front in this
section. TEST the system for
normal operation.
DISCONNECThe battery ground

cable. CONNECT driver safety
belt buckle pretensioner C3049.

bag module C3051.

Section 501-20B .
No
REPAIR the circuit. TEST the
DISCONNECT the battery

ground cable. CONNECT driver
safety belt buckle pretensioner
C3049.

bag module C3051.

Section 501-20B .
Pinpoint Test C: The Power Seat is Inoperative - Passenger, With Power Recliner
Normal Operation
The passenger seat control switch is powered by battery voltage on circuit SBB29 (GY/RD) and is supplied
ground on circuit GD138 (BK/WH). When pressed, the seat control switch supplies that voltage and ground to
reverses the polarity to that same power seat track motor, which moves the seat in the opposite direction.
There are 3 power seat track motors that combine to move the seat cushion horizontally (forward/rearward)
and vertically (front up/down and rear up/down). If a new seat track motor needs to be installed, it is
necessary to install an entire power seat track.

Fuse
Seat control switch

PINPOINT TEST C: THE POWER SEAT IS INOPERATIVE - PASSENGER, WITH POWER RECLINER

C1 CHECK FOR VOLTAGE TO THE SEAT
CONTROL SWITCH
Yes
General ocedures portion of Section 501-20B . VERIFY Battery Junction Box (BJB) fuse
Disconnect: Passenger Seat Safety Belt Buckle 22 (30A) is OK. If OK, REPAIR the
Pretensioner C3050. circuit. If not OK, REFER to the Wiring
Disconnect: Passenger Seat Side Air Bag C3052. Diagrams manual to identify possible
Disconnect: Passenger Seat Control Switch C3026. causes of the circuit short. TEST the
WARNING: Make sure no one is in the vehicle system for normal operation.
any air bag module when the battery is connected. DISCONNECT the battery ground cable.
Failure to follow these instructions may result in CONNECT passenger safety belt buckle
serious personal injury in the event of an pretensioner C3050.
Connect the battery ground cable. Refer to Section CONNECT passenger seat side air bag
414-01 . module C3052.
Measure the voltage between passenger seat control
switch C3026-5, circuit SBB29 (GY/RD), harness REPOWER the SRS . REFER to Section
side and ground. 501-20B .

C2 CHECK THE SEAT CONTROL SWITCH
Yes
Measure the resistance between passenger seat INSTALL a new passenger seat control
control switch C3026-3, circuit GD138 (BK/WH), switch. REFER to Seat Control Switch -
harness side and ground. Front in this section. TEST the system for
normal operation.

CONNECT passenger safety belt buckle
pretensioner C3050.
PINPOINT TEST C: THE POWER SEAT IS INOPERATIVE - PASSENGER, WITH POWER RECLINER
372
CONNECT passenger seat side air bag

module C3052.

501-20B .
No
normal operation.

CONNECT passenger safety belt buckle
pretensioner C3050.
CONNECT passenger seat side air bag

module C3052.

501-20B .
Pinpoint Test D: The Power Seat is Inoperative - Passenger, With Manual Recliner
Normal Operation
and vertically (front up/down and rear up/down). If a new seat track motor needs to be installed, it is
necessary to install an entire power seat track.

Fuse
Seat control switch
PINPOINT TEST D: THE POWER SEAT IS INOPERATIVE - PASSENGER, WITH MANUAL RECLINER
Test StepResult / Action to Take D1 CHECK FOR VOLTAGE TO THE SEAT CONTROL SWITCH
Ignition OFF.
Depower the SRS . Refer to Supplemental Restraint System (SRS) Depowering and Repowering in
the General Procedures portion of Section 501-20B .

Disconnect: Passenger Seat Safety Belt Buckle Pretensioner C3050.
Disconnect: Passenger Seat Side Air Bag C3052.
Disconnect: Passenger Seat Control Switch C355.
WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in
front of any air bag module when the battery is connected. Failure to follow these instructions
may result in serious personal injury in the event of an accidental deployment.
Connect the battery ground cable. Refer to Section 414-01 .
Measure the voltage between passenger seat control switch C355-4, circuit SBB29 (GY/RD), harness
side and ground.
Yes
GO to D2 .
No
VERIFY Battery Junction Box (BJB) fuse 22 (30A) is OK. If OK, REPAIR the circuit. If not OK, REFER to
the Wiring Diagrams manual to identify possible causes of the circuit short. TEST the system for normal
operation.
DISCONNECT the battery ground cable. CONNECT passenger safety belt buckle pretensioner C3050.
CONNECT passenger seat side air bag module C3052.
REPOWER the SRS . REFER to Section 501-20B . D2 CHECK THE SEAT CONTROL SWITCH
Measure the resistance between passenger seat control switch C355-2, circuit GD138 (BK/WH),
Yes
INSTALL a new passenger seat control switch. REFER to Seat Control Switch - Front in this section. TEST
the system for normal operation.
PINPOINT TEST D: THE POWER SEAT IS INOPERATIVE - PASSENGER, WITH MANUAL RECLINER
374
CONNECT passenger seat side air bag module C3052.
REPOWER the SRS . REFER to Section 501-20B .
No
CONNECT passenger seat de air bag module C3052.
REPOWER the SRS . REFER to Section 501-20B .
Pinpoint Test H: The Power Seat Does Not Move Horizontally/Vertically/Recline - Driver, With Power
Recliner
Normal Operation
up/down). There is an additional motor in the power recline mechanism to ve the seat backrest forward and
The power recliner motor is serviced with the seat backrest frame.

Seat control switch
Seat track motor (seat track)
Power recliner mechanism
PINPOINT TEST H: THE POWER SEAT DOES NOT MOVE HORIZONTALLY/VERTICALLY/RECLINE - DRIVER, WITH
POWER RECLINER

H1 CHECK THE HORIZONTAL MOTOR FOR CORRECT
OPERATION
Yes
Operate the driver power seat forward and rearward. GO to H2 .
Will the seat move horizontally?
No

GO to H3 .
H2 CHECK THE RECLINER MOTOR FOR CORRECT
OPERATION
Yes
Recline the driver backrest forward and rearward. GO to H6 .
Will the seat backrest recline forward and rearward?
No
GO to H13 .
H3 CHECK FOR VOLTAGE TO THE HORIZONTAL
MOTOR
Yes
Ignition OFF. INSTALL a new driver seat track
Depower the SRS . Refer to Supplemental Restraint System assembly. REFER to Seat Track -
(SRS) Depowering and Repowering in the General Power in this section. TEST the
Procedures portion of Section 501-20B . system for normal operation.
Disconnect: Driver Seat Safety Belt Buckle Pretensioner
C3049. DISCONNECT the battery ground
Disconnect: Driver Seat Side Air Bag C3051. cable. CONNECT driver safety
Disconnect: Horizontal Seat Motor C362. belt buckle pretensioner C3049.
WARNING: Make sure no one is in the vehicle and
there is nothing blocking or placed in front of any air CONNECT driver seat side air bag
bag module when the battery is connected. Failure to module C3051.
follow these instructions may result in serious personal
injury in the event of an accidental deployment. REPOWER the SRS . REFER to
Connect the battery ground cable. Refer to Section 414-01 . Section 501-20B .
Measure the voltage between driver seat horizontal motor
C362-3, circuit CPS28 (GN), harness side and C362-4, No
circuit CPS23 (GN/VT), harness side, while pushing the GO to H4 .
driver seat control switch forward and rearward.
Is the voltage greater than 10 volts when the seat control

switch is operated in both directions and 0 volt in the
rest position?
H4 CHECK THE HORIZONTAL MOTOR CIRCUIT FOR
AN OPEN
Yes
Disconnect: Driver Seat Control Switch C3016. GO to H5 .
Measure the resistance between driver seat control switch
C3016-9, circuit CPS28 (GN), harness side and driver seat No
horizontal motor C362-3, circuit CPS28 (GN), harness side. REPAIR the circuit. TEST the
DISCONNECT the battery ground

PINPOINT TEST H: THE POWER SEAT DOES NOT MOVE HORIZONTALLY/VERTICALLY/RECLINE

376 - DR

module C3051.

Section 501-20B .
H5 CHECK THE HORIZONTAL MOTOR CIRCUIT FOR
AN OPEN
Yes
Measure the resistance between driver seat control switch INSTALL a new driver seat
C3016-4, circuit CPS23 (GN/VT), harness side and driver control switch. REFER to Seat
seat horizontal motor C362-4, circuit CPS23 (GN/VT), Control Switch - Front in this
harness side. section. TEST the system for
normal operation.


module C3051.

Section 501-20B .
No


module C3051.

Section 501-20B .
H6 DETERMINE THE SEAT HEIGHT ADJUST FAILURE
Yes
Operate the frt and rear seat height adjustments. If only front height adjust operates,
Does the seat front and rear height adjust up and down? GO to H7 .
If only rear height adjust operates,

GO to H10 .
No
INSTALL a new driver seat
normal operation.

377 - DR


module C3051.

Seion 501-20B .
H7 CHECK FOR VOLTAGE TO THE REAR HEIGHT
MOTOR
Yes
Disconnect: Driver Seat Rear Height Motor C363. belt buckle pretensioner C3049.
Measure the voltage between driver seat rear height motor
C363-3, circuit CPS27 (BU/BN), harness side and C363-4, No
circuit CPS26 (YE/BU), harness side, while depressing the GO to H8 .
seat control switch rear height adjust up and down.

rest position?
H8 CHECK THE REAR HEIGHT MOTOR CIRCUIT FOR
AN OPEN
Yes
C3016-1, circuit CPS27 (BU/BN), harness side and driver No
seat rear height motor C363-3, circuit CPS27 (BU/BN), REPAIR the circuit. TEST the
harness side. system for normal operation.

378 - DR


module C3051.

Section 501-20B .
H9 CHECK THE REAR HEIGHT MOTOR CIRCUIT FOR
AN OPEN
Yes
C3016-12, circuit CPS26 (YE/BU), harness side and driver control switch. REFER to Seat
seat rear height motor C363-4, circuit CPS26 (YE/BU), Control Switch - Front in this
normal operation.


module C3051.

Section 501-20B .
No


module C3051.

Section 501-20B .
H10 CHECK FOR VOLTAGE TO THE FRONT HEIGHT
MOTOR
Yes
Disconnect: Driver Seat Front Height Motor C382. belt buckle pretensioner C3049.

379 - DR
WARNING: Make sure no one is in the vehicle and CONNECT driver seat side air bag
there is nothing blocking or placed in front of any air module C3051.
bag module when the battery is connected. Failure to
follow these instructions may result in serious personal REPOWER the SRS . REFER to
injury in the event of an accidental deployment. Section 501-20B .
Measure the voltage between driver seat front height motor No
C382-3, circuit CPS25 (WH/VT), harness side and C382-4, GO to H11 .
circuit CPS24 (GY), while pushing the seat control switch
front height adjust up and down.

rest position?
H11 CHECK THE FRONT HEIGHT MOTOR CIRCUIT
FOR AN OPEN
Yes
C3016-2, circuit CPS25 (WH/VT), harness side and driver No
seat front height motor C382-3, circuit CPS25 (WH/VT), REPAIR the circuit. TEST the


module C3051.

Section 501-20B .
H12 CHECK THE FRONT HEIGHT MOTOR CIRCUIT
FOR AN OPEN
Yes
C3016-6, circuit CPS24 (GY) harness side, and driver seat control switch. REFER to Seat
front height motor C382-4, circuit CPS24 (GY), harness Control Switch - Front in this
side. section. TEST the system for
normal operation.


380 - DR

module C3051.

Section 501-20B .
No


module C3051.

Section 501-20B .
H13 CHECK FOR VOLTAGE TO THE RECLINER MOTOR
Yes
Ignition OFF. INSTALL a new driver seat
Depower the SRS . Refer to Supplemental Restraint System recliner motor. TEST the system
(SRS) Depowering and Repowering in the General for normal operation.
Procedures portion of Section 501-20B .
Disconnect: Driver Seat Safety Belt Buckle Pretensioner DISCONNECT the battery ground
C3049. cable. CONNECT driver safety
Disconnect: Driver Seat Side Air Bag C3051. belt buckle pretensioner C3049.
Disconnect: Driver Seat Recliner Motor C3187.
WARNING: Make sure no one is in the vehicle and CONNECT driver seat side air bag
there is nothing blocking or placed in front of any air module C3051.
Measure the voltage between driver seat recliner motor No
C3187-1, circuit CPS08 (VT/OG), harness side and GO to H14 .
C3187-2, circuit CPS07 (GY/BN), while pushing the recline
switch forward and rearward.

rest position?

381 - DR
H14 CHECK THE RECLINER MOTOR CIRCUITS FOR AN

OPEN
Yes
C3016-11, circuit CPS29 (WH/BN), harness side and driver No
seat recliner motor C3187-2, circuit CPS07 (GY/BN), REPAIR the circuit(s). TEST the


module C3051.

Section 501-20B .
H15 CHECK THE RECLINER MOTOR CIRCUITS FOR AN
OPEN
Yes
C3016-8, circuit CPS30 (VT/BN), harness side, and driver control switch. REFER to Seat
seat recliner motor C3187-1, circuit CPS08 (VT/OG), Control Switch - Front in this
normal operation.


module C3051.

Section 501-20B .
No
REPAIR the circuit(s). TEST the


module C3051.

Section 501-20B .

382 - DR
Pinpoint Test I: The Power Seat Does Not Move Horizontally/Vertically - Driver, With Manual
Recliner
Normal Operation
and vertically (front up/down and rear up/down). If a new motor needs to be installed, it is necessary to install
an entire power seat track.

Seat control switch
PINPOINT TEST I: THE POWER SEAT DOES NOT MOVE HORIZONTALLY/VERTICALLY - DRIVER, WITH MANUAL
RECLINER
removed the ignition is ON.

I1 CHECK THE HORIZONTAL MOTOR FOR CORRECT
OPERATION
Yes
Operate the driver power seat forward and rearward. GO to I5 .
No
GO to I2 .
I2 CHECK FOR VOLTAGE TO THE HORIZONTAL
MOTOR
Yes
Disconnect: Driver Seat Horizontal Motor C362. belt buckle pretensioner C3049.


Measure the voltage between driver seat horizontal motor
C362-3, circuit CPS28 (GN), harness side and C362-4, No
circuit CPS23 (GN/VT), harness side, while pushing the GO to I3 .
driver seat control switch forward and rearward.

rest position?
I3 CHECK THE HORIZONTAL MOTOR CIRCUIT FOR AN
OPEN
Yes
Disconnect: Driver Seat Control Switch C352. GO to I4 .
C352-6, circuit CPS28 (GN), harness side and driver seat No
horizontal motor C362-3, circuit CPS28 (GN), harness side. REPAIR the circuit. TEST the


module C3051.

Section 501-20B .
I4 CHECK THE HORIZONTAL MOTOR CIRCUIT FOR AN
OPEN
Yes
C352-3, circuit CPS23 (GN/VT), harness side and driver control switch. REFER to Seat
seat horizontal motor C362-4, circuit CPS23 (GN/VT), Control Switch - Front in this
normal operation.


module C3051.
PINPOINT TEST I: THE POWER SEAT DOES NOT MOVE HORIZONTALLY/VERTICALLY - DRIVER,
384 WIT
Is the resistance less than 5 ohms? Section 501-20B .
No


module C3051.

Section 501-20B .
I5 DETERMINE THE SEAT HEIGHT ADJUST FAILURE
Yes
Operate the front and rear seat height adjustments. If only front height adjust operates,
Does the seat front and rear height adjust up and down? GO to I6 .

GO to I9 .
No
INSTALL a new driver seat
normal operation.


module C3051.

Section 501-20B .
I6 CHECK FOR VOLTAGE TO THE REAR HEIGHT
MOTOR
Yes
Disconnect: Driver Seat Rear Height Motor C363. belt buckle pretensioner C3049.
385 WIT

Measure the voltage between driver seat rear height motor
C363-3, circuit CPS27 (BU/BN), harness side and C363-4, No
circuit CPS26 (YE/BU), harness side, while depressing the GO to I7 .
seat control switch rear height adjust up and down.

rest position?
I7 CHECK THE REAR HEIGHT MOTOR CIRCUIT FOR
AN OPEN
Yes
Disconnect: Driver Seat Control Switch C352. GO to I8 .
C352-5, circuit CPS27 (BU/BN), harness side and driver No
seat rear height motor C363-3, circuit CPS27 (BU/BN), REPAIR the circuit. TEST the


module C3051.

Section 501-20B .
I8 CHECK THE REAR HEIGHT MOTOR CIRCUIT FOR
AN OPEN
Yes
C352-7, circuit CPS26 (YE/BU), harness side and driver control switch. REFER to Seat
seat rear height motor C363-4, circuit CPS26 (YE/BU), Control Switch - Front in this
normal operation.


module C3051.
386 WIT
REPOWER the SRS . REF to

Section 501-20B .
No

module C3051.

Section 501-20B .
I9 CHECK FOR VOLTAGE TO THE FRONT HEIGHT
MOTOR
Yes
Disconnect: Driver Seat Front Height Motor C382. belt buckle pretensioner C3049.
Measure the voltage between driver seat front height motor
C382-3, circuit CPS25 (WH/VT), harness side and C382-4, No
circuit CPS24 (GY), while pushing the seat control switch GO to I10 .
front height adjust up and down.

rest position?
I10 CHECK THE FRONT HEIGHT MOTOR CIRCUIT FOR
AN OPEN
387 WIT
Disconnect: Driver Seat Control Switch C352. Yes

Measure the resistance between driver seat control switch GO to I11 .
C352-1, circuit CPS25 (WH/VT), harness side and driver
seat front height motor C382-3, circuit CPS25 (WH/VT), No
harness side. REPAIR the circuit. TEST the


module C3051.

Section 501-20B .
I11 CHECK THE FRONT HEIGHT MOTOR CIRCUIT FOR
AN OPEN
Yes
C352-8, circuit CPS24 (GY), harness side, and driver seat control switch. REFER to Seat
front height motor C382-4, circuit CPS24 (GY), harness Control Switch - Front in this
side. section. TEST the system for
normal operation.


module C3051.

Section 501-20B .
No


module C3051.

Section 501-20B .
Pinpoint Test The Power Seat Does Not Move Horizontally/Vertically/Recline - Passenger, With Power
Recliner
388 WIT
Normal Operation
up/down). There is an additional motor in the power recline mechanism to move the seat backrest forward and
The power recline motor is serviced with the backrest frame.

Seat control switch
Power recliner mechanism
PINPOINT TEST J: THE POWER SEAT DOES NOT MOVE HORIZONTALLY/VERTICALLY/RECLINE - PASSENGER,
WITH POWER RECLINER
NOTE: Tir bag warning indicator illuminates when the correct Restraints Control Module (RCM) fuse is

J1 CHECK THE HORIZONTAL MOTOR FOR CORRECT
OPERATION
Yes
Operate the passenger power seat forward and rearward. GO to J2 .
No
GO to J3 .
J2 CHECK THE RECLINER MOTOR FOR CORRECT
OPERATION
Yes
Recline the passenger backrest forward and rearward. GO to J6 .
Will the seat backrest recline forward and rearward?
No
GO to J13 .
J3 CHECK FOR VOLTAGE TO THE HORIZONTAL
MOTOR
Yes
Ignition OFF. INSTALL a new passenger seat
Depower the SRS . Refer to Supplemental Restraint System track assembly. REFER to Seat
(SRS) Depowering and Repowering in the General Track - Power in this section.
Procedures portion of Section 501-20B . TEST the system for normal
Disconnect: Passenger Seat Safety Belt Buckle Pretensioner operation.
C3050.

Disconnect: Passenger Seat Side Air Bag C3052. DISCONNECT the battery ground
Disconnect: Passenger Seat Horizontal Motor C332. cable. CONNECT passenger safety
WARNING: Make sure no one is in the vehicle and belt buckle pretensioner C3050.
there is nothing blocking or placed in front of any air
bag module when the battery is connected. Failure to CONNECT passenger seat side air
follow these instructions may result in serious personal bag module C3052.
injury in the event of an accidental deployment.
Connect the battery ground cable. Refer to Section 414-01 . REPOWER the SRS . REFER to
Measure the voltage between passenger seat motor C332-3, Section 501-20B .
circuit CPS38 (GN/BU), harness side and C332-4, circuit
CPS33 (WH), harness side, while pushing the passenger No
seat control switch forward and rearward. GO to J4 .

rest position?
J4 CHECK THE HORIZONTAL MOTOR CIRCUIT FOR
AN OPEN
Yes
Disconnect: Passenger Seat Control Switch C3026. GO to J5 .
Measure the resistance between passenger seat control
switch C3026-9, circuit CPS38 (GN/BU), harness side and No
passenger seat horizontal motor C332-3, circuit CPS38 REPAIR the circuit. TEST the
(GN/BU), harness side. system for normal operation.

cable. CONNECT passenger safety
CONNECT passenger seat side air

bag module C3052.

Section 501-20B .
J5 CHECK THE HORIZONTAL MOTOR CIRCUIT FOR
AN OPEN
Yes
Measure the resistance between passenger seat control INSTALL a new passenger seat
switch C3026-4, circuit CPS33 (WH), harness side and control switch. REFER to Seat
passenger seat horizontal motor C332-4, circuit CPS33 Control Switch - Front in this
(WH), harness side. section. TEST the system for
normal operation.
PINPOINT TEST J: THE POWER SEAT DOES NOT MOVE HORIZONTALLY/VERTICALLY/RECLINE

390 - PA


bag module C3052.

Section 501-20B .
No


bag module C3052.

Section 501-20B .
J6 DETERMINE THE SEAT HEIGHT ADJUST FAILURE
Yes
Operate the front and rear seat height adjustments. If only front height adjust operates,
Does the seat front and rear height adjust up and down? GO to J7 .

GO to J10 .
No
INSTALL a new passenger seat
normal operation.


bag module C3052.

Section 501-20B .
J7 CHECK FOR VOLTAGE TO THE REAR HEIGHT
MOTOR

391 - PA
Ignition OFF. Yes

Depower the SRS . Refer to Supplemental Restraint System INSTALL a new passenger seat
(SRS) Depowering and Repowering in the General track assembly. REFER to Seat
Procedures portion of Section 501-20B . Track - Power in this section.
Disconnect: Passenger Seat Safety Belt Buckle Pretensioner TEST the system for normal
C3050. operation.
Disconnect: Passenger Seat Rear Height Motor C3075. DISCONNECT the battery ground
WARNING: Make sure no one is in the vehicle and cable. CONNECT passenger safety
there is nothing blocking or placed in front of any air belt buckle pretensioner C3050.
follow these instructions may result in serious personal CONNECT passenger seat side air
injury in the event of an accidental deployment. bag module C3052.
Measure the voltage between passenger seat rear height REPOWER the SRS . REFER to
motor C3075-3, circuit CPS37 (WH/BU), harness side and Section 501-20B .
C3075-4, circuit CPS36 (YE/GY), harness side, while
depressing the seat control switch rear height adjust up and No
down. GO to J8 .

rest position?
J8 CHECK THE REAR HEIGHT MOTOR CIRCUIT FOR
AN OPEN
Yes
switch C3026-12, cirit CPS37 (WH/BU), harness side and No
passenger seat rear height motor C3075-3, circuit CPS37 REPAIR the circuit. TEST the
(WH/BU), harness side. system for normal operation.


bag module C3052.

Section 501-20B .
J9 CHECK THE REAR HEIGHT MOTOR CIRCUIT FOR
AN OPEN

392 - PA
Measure the resistance between passenger seat control Yes

switch C3026-1, circuit CPS36 (YE/GY), harness side and INSTALL a new passenger seat
passenger seat rear height motor C3075-4, circuit CPS36 control switch. REFER to Seat
(YE/GY), harness side. Control Switch - Front in this
normal operation.


bag module C3052.
Section 501-20B .
No


bag module C3052.

Section 501-20B .
J10 CHECK FOR VOLTAGE TO THE FRONT HEIGHT
MOTOR
Yes
C3050.
Disconnect: Passenger Seat Front Height Motor C3074. cable. CONNECT passenger safety
Measure the voltage between passenger seat front height Section 501-20B .
motor C3074-3, circuit CPS35 (VT/GN), harness side and
C3074-4, circuit CPS34 (GY/BU), while pushing the seat No
control switch front height adjust up and down. GO to J11 .

393 - PA

rest position?
J11 CHECK THE FRONT HEIGHT MOTOR CIRCUIT FOR
AN OPEN
Yes
switch C3026-6, circuit CPS35 (VT/GN), harness side and No
passenger seat front height motor C3074-3, circuit CPS35 REPAIR the circuit. TEST the
(VT/GN), harness side. system for normal operation.


bag module C3052.

Section 501-20B .
J12 CHECK THE FRONT HEIGHT MOTOR CIRCUIT FOR
AN OPEN
Yes
switch C3026-2, circuit CPS34 (GY/BU), harness side, and control switch. REFER to Seat
passenger seat front height motor C3074-4, circuit CPS34 Control Switch - Front in this
(GY/BU), harness side. section. TEST the system for
normal operation.


bag module C3052.

Section 501-20B .
No


394 - PA

bag module C3052.

Section 501-20B .
J13 CHECK FOR VOLTAGE TO THE RECLINER MOTOR
Yes
Depower the SRS . Refer to Supplemental Restraint System recliner motor. TEST the system
(SRS) Depowering and Repowering in the General for normal operation.
Procedures portion of Section 501-20B .
Disconnect: Passenger Seat Safety Belt Buckle Pretensioner DISCONNECT the battery ground
C3050. cable. CONNECT passenger safety
Disconnect: Passenger Seat Side Air Bag C3052. belt buckle pretensioner C3050.
Disconnect: Passenger Seat Recliner Motor C3189.
WARNING: Make sure no one is in the vehicle and CONNECT passenger seat side air
there is nothing blocking or placed in front of any air bag module C3052.
Measure the voltage between passenger seat recliner motor No
C3189-1, circuit CPS08 (VT/OG), harness side and GO to J14 .
C3189-2, circuit CPS07 (GY/BN), while pushing the recline
switch forward and rearward.

rest position?
J14 CHECK THE RECLINER CIRCUITS FOR AN OPEN
Yes
switch C3026-11, circuit CPS39 (GY/YE), harness side and No
passenger seat recliner motor C3189-2, circuit CPS07 REPAIR the circuit(s). TEST the
(GY/BN), harness side. system for normal operation.


bag module C3052.

395 - PA

Section 501-20B .

J15 CHECK THE RECLINER CIRCUITS FOR AN OPEN
Yes
switch C3026-8, circuit CPS40 (VT/GY), harness side, and control switch. REFER to Seat
passenger seat recliner motor C3189-1, circuit CPS08 Control Switch - Front in this
(VT/OG), harness side. section. TEST the system for
normal operation.


bag module C3052.

Section 501-20B .
No
REPAIR the circuit(s). TEST the


bag module C3052.

Section 501-20B .
Pinpoint Test K: The Power Seat Does Not Move Horizontally/Vertically - Passenger, With Manual
Recliner
Normal Operation
and vertically (front up/down and rear up/down). If a new motor needs to be installed, it is necessary to install

an entire power seat track.

Seat control switch
PINPOINT TEST K: THE POWER SEAT DOES NOT MOVE HORIZONTALLY/VERTICALLY - PASSENGER, WITH
MANUAL RECLINER

K1 CHECK THE HORIZONT MOTOR FOR CORRECT
OPERATION
Yes
Operate the passenger power seat forward and rearward. GO to K5 .
No
GO to K2 .
K2 CHECK FOR VOLTAGE TO THE HORIZONTAL
MOTOR
Yes
C3050.
Disconnect: Passenger Seat Horizontal Motor C332. cable. CONNECT passenger safety
Measure the voltage between passenger seat horizontal Section 501-20B .
motor C332-3, circuit CPS38 (GN/BU), harness side and
C332-4, circuit CPS33 (WH), harness side, while pushing No
the passenger seat control switch forward and rearward. GO to K3 .
PINPOINT TEST K: THE POWER SEAT DOES NOT MOVE HORIZONTALLY/VERTICALLY - PASSENGER
397

rest position?
K3 CHECK THE HORIZONTAL MOTOR CIRCUIT FOR
AN OPEN
Yes
Disconnect: Passenger Seat Control Switch C355. GO to K4 .
switch C355-6, circuit CPS38 (GN/BU), harness side and No
passenger seat horizontal motor C332-3, circuit CPS38 REPAIR the circuit. TEST the
(GN/BU), harness side. system for normal operation.


bag module C3052.

Section 501-20B .
K4 CHECK THE HORIZONTAL MOTOR CIRCUIT FOR
AN OPEN
Yes
switch C355-3, circuit CPS33 (WH), harness side and control switch. REFER to Seat
passenger seat horizontal motor C332-4, circuit CPS33 Control Switch - Front in this
(WH), harness side. section. TEST the system for
normal operation.


bag module C3052.

Section 501-20B .
No

398

bag module C3052.

Section 501-20B .
K5 DETERMINE THE SEAT HEIGHT ADJUST FAILURE
Yes
Operate the front and rear seat hght adjustments. If only front height adjust operates,
Does the seat front and rear height adjust up and down? GO to K6 .

GO to K9 .
No
INSTALL a new passenger seat
normal operation.


bag module C3052.

Section 501-20 .
K6 CHECK FOR VOLTAGE TO THE REAR HEIGHT
MOTOR
Yes
C3050.
Disconnect: Passenger Seat Rear Height Motor C3075. cable. CONNECT passenger safety
Measure the voltage between passenger seat rear height Section 501-20B .
motor C3075-3, circuit CPS37 (WH/BU), harness side and
C3075-4, circuit CPS36 (YE/GY), harness side, while No
depressing the seat control switch rear height adjust up and GO to K7 .
down.
399

rest position?
K7 CHECK THE REAR HEIGHT MOTOR CIRCUIT FOR
AN OPEN
Yes
switch C355-5, circuit CPS36 (YE/GY), harness side and No
passenger seat rear height motor C3075-4, circuit CPS36 REPAIR the circuit. TEST the
(YE/GY), harness side. system for normal operation.


bag module C3052.

Section 501-20B .
K8 CHECK THE REAR HEIGHT MOTOR CIRCUIT FOR
AN OPEN
Yes
switch C355-7, circuit CPS37 (WH/BU), harness side and control switch. REFER to Seat
passenger seat rear height motor C3075-3, circuit CPS37 Control Switch - Front in this
(WH/BU), harness side. section. TEST the system for
normal operation.


bag module C3052.

Section 501-20B .
No
400


bag module C3052.

Section 501-20B .
K9 CHECK FOR VOLTAGE TO THE FRONT HEIGHT
MOTOR
Yes
(SRS) Depowering and Repowering in the General Track - Por in this section. TEST
Procedures portion of Section 501-20B . the system for normal operation.
Disconnect: Passenger Seat Safety Belt Buckle Pretensioner
Disconnect: Passenger Seat Side Air Bag C3052. cable. CONNECT passenger safety
Disconnect: Passenger Seat Front Height Motor C3074. belt buckle pretensioner C3050.
there is nothing blocking or placed in front of any air CONNECT passenger seat side air
bag module when the battery is connected. Failure to bag module C3052.
Measure the voltage between passenger seat front height
motor C3074-3, circuit CPS35 (VT/GN), harness side and No
C3074-4, circuit CPS34 (GY/BU), while pushing the seat GO to K10 .
control switch rear height adjust up and down.

rest position?
K10 CHECK THE FRONT HEIGHT MOTOR CIRCUIT
FOR AN OPEN
Yes
switch C355-8, circuit CPS35 (VT/GN), harness side and No
passenger seat front height motor C3074-3, circuit CPS35 REPAIR the circuit. TEST the
(VT/GN), harness side. system for normal operation.

401

bag module C3052.

Section 501-20B .
K11 CHECK THE FRONT HEIGHT MOTOR CIRCUIT
FOR AN OPEN
Yes
switch C355-1, circuit CPS34 (GY/BU), harness side, and control switch. REFER to Seat
passenger seat front height motor C3074-4, circuit CPS34 Control Switch - Front in this
(GY/BU), harness side. section. TEST the system for
normal operation.


bag module C3052.

Section 501-20B .
No


bag module C3052.

Section 501-20B .
Pinpoint Test L: The Memory Seat is Inoperative/Does Not Operate Correctly - Does Not Operate
Horizontally/Vertically/Recline
Refer to Wiring DiagrCell 123 , Memory Seats for schematic and connector information.
Refer to Wiring Diagrams Cell 149 , Component Testing for component testing.
Normal Operation
The driver seat control switch is powered by battery voltage on circuit SBP12 (GN/RD) and is supplied
ground on circuit GD133 (BK). When pressed, the seat control switch supplies voltage and ground to the
applicable Driver Seat Module (DSM) inputs. The DSM then supplies voltage and ground to the appropriate

power seat track motor or power recline motor based on the inputs received from the seat control switch.
When pressed in the opposite direction, the seat control switch reverses the polarity to the DSM inputs, and
the DSM likewise reverses polarity of the appropriate power seat track motor or power recliner motor circuits
causing the seat or backrest to move in the opposite direction. There are 3 power seat track motors that
combine to move the seat horizontally (forward/rearward) and vertically (front up/down and rear up/down).
The seat backrest power recliner mechanism uses a single motor to move the seat backrest forward and
rearward.
Battery voltage is also supplied to the DSM on circuits SBP02 (YE/RD) and SBB74 (YE/RD). Ground is
supplied to the DSM on circuits GD133 (BK) and GD143 (BK/VT).
Each motor in the memory power seat track and power recliner mechanism contains a Hall-effect position
sensor. The DSM supplies a shared signal feed circuit to each position sensor. Each position sensor sends a
signal pulse back to the DSM to monitor the position of the power seat and seat backrest. The DSM uses this
information to return the seat to a stored pre-programmed position when pressing the memory SET switch or a
Remote Keyless Entry (RKE) transmitter. For information on programming memory positions or recalling a
stored memory position, refer to Memory Position Programming in this section.
The following pinpoint test diagnoses a memory seat that does not operate in one or more directions when
using the seat control switch. If the memory seat moves in all directions using the seat control switch, but does
not operate using the memory SET switch, GO to Pinpoint Test M .

If a programming error is detected, the DTC is set.
B1342 - ECU is
Faulted
During self-test, the DSM attempts to operate the appropriate seat track motor
B1663 - Seat Driver and uses the motor's position sensor to monitor movement. If no motor
Front Up/Down movement is sensed, the DTC is set. The DSM will retry motor operation on
Motor Stalled the next activation of the seat control If no movement continues to be
B1664 - Seat Driver monitored after 250 milliseconds, the DSM disables the output.
Rear Up/Down
Motor Stalled
B1665 - Seat Driver
Forward/Backward
Motor Stalled
During self-test, the DSM attempts to operate the recliner motor and uses the
B1666 - Seat Driver recliner motor position sensor to monitor movement. If no motor movement is
Recline Motor sensed, the DTC is set. The DSM will retry motor operation on the next
Stalled activation of the seat control switch. If no motor movement is still monitored
after 250 milliseconds, the DSM disables the output.
If voltage is sensed on the switch input circuit during the DSM self-test, the
B1703 - Seat Driver DTC is set. If voltage is sensed on the input circuit for greater than 2 minutes
Recline Forward the DTC is set as continuous. With the DTC set, any input signal on the circuit
Switch Circuit Short is ignored.
to Battery
B1707 - Seat Driver
Recline Rearward
Switch Circuit Short
to Battery

B1711 - Seat Driver If voltage is sensed on the switch input circuit during the DSM self-test, the
Front Up Switch DTC is set. If voltage is sensed on the input circuit for greater than 2 minutes
Circuit Short to the DTC is set as continuous. With the DTC set, any input signal on the circuit
Battery is ignored.
B1715 - Seat Driver
Front Down Switch
Circuit Short to
Batte/ul>
Forward Switch the DTC is set as continuous. With the DTC set, any input signal on the circuit
Circuit Short to is ignored.
Battery
B1723 - Seat Driver
Rearward Switch
Circuit Short to
Battery
Rear Up Switch the DTC is set as continuous. With the DTC set, any input signal on the circuit
Circuit Short to is ignored.
Battery
B1731 - Seat Driver
Rear Down Switch
Circuit Short to
Battery

Fuse
Seat control switch
Missing status information - Medium Speed Controller Area Network (MS-CAN) communication bus
messages:
DSM
PINPOINT TEST L: THE MEMORY SEAT IS INOPERATIVE/DOES NOT OPERATE CORRECTLY - DOES NOT
OPERATE HORIZONTALLY/VERTICALLY/RECLINE
NOTE: If a new DSM has been installed, all seat and power steering column (if equipped) soft stops must be
reset. If a new seat track, recline motor or power steering column has been installed, only reset the soft stops
for that component being installed new. To reset the soft stops, refer to Principles of Operation in this section.
PINPOINT TEST L: THE MEMORY SEAT IS INOPERATIVE/DOES NOT OPERATE CORRECTLY

404- DOES
NOTE: Verify the PID states agree with the ignition and transmission gear selector in all positions before
proceeding with memory seat diagnosis.

L1 CHECK TRANSMISSION GEAR SELECTOR
TRANSMISSION RANGE (TR) PID STATES
Yes
Enter the following diagnostic mode on the scan tool: GO to L2 .
DataLogger - TCM - PID: TR.
Operate the transmission gear selector in all positions No
while monitoring the TCM PID TR states. To diagnose a transmission gear selector
Do the PID states agree with the selected (PRNDL) status concern, REFER to
positions? Section 307-01 .
L2 CHECK IGNITION SWITCH PIDs
Yes
DataLogger - IC - PIDs.
ACC Position (IGN_A) No
Ignition Switch - Off/Unlock Position To diagnose an ignition switch status
(IGN_O/U) concern, REFER to Section 211-05 .
Ignition Switch - Run Position (IGN_R)
Start (Position 3) (IGN_S)
Cycle the ignition in all positions while monitoring
the Instrument Cluster (IC) ignition switch input
status PIDs.
Do the PIDs agree with lected positions?
L3 RETRIEVE THE DSM DTCs
Yes
Operate the memory seat, memory mirrors, adjustable If DTCs B1663, B1664, B1665 and
memory pedals (if equipped) and adjustable memory B1666 are all retrieved, GO to L12 .
steering column (if equipped) in all directions through
the full range of travel. If DTC B1663, GO to L22 .
Place the memory seat, memory mirrors, adjustable
memory pedals (if equipped) and adjustable memory If DTC B1664, GO to L25 .
steering column (if equipped) in central travel
positions. If DTC B1665, GO to L28 .
Self Test - DSM . If DTC B1666, GO to L31 .
Are any DSM DTCs retrieved?
If DTC B1703, GO to L5 .

405- DOES
If DTC B1342, INSTALL a new DSM .

REFER to Driver Seat Module (DSM) in
this section. CLEAR the DTCs. REPEAT
the self-test.
For any other DSM DTCs, REFER to the

Driver Seat Module (DSM) DTC Chart.
No
GO to L4 .
L4 MONITOR THE DSM PIDs AND CHECK FOR
CORRECT MEMORY SEAT SWITCH INPUTS
Yes
DataLogger - DSM - PIDs.
Driver Power Seat Front Up/Down Switch No
(SFNT_SW) VERIFY Smart Junction Box (SJB) fuse
Driver Power Seat Forward/Backward Switch 12 (7.5A) is OK.
(SFWD_SW)
Driver Power Seat Recline Switch Status If the fuse fails while operating the seat
(SRCL_SW) control switch, DISCONNECT the seat
Driver Power Seat Rear Up/Down Switch control switch C3016 and GO to L9 .
(SREARSW)
Operate the seat control switch in all positions while If the fuse is OK, GO to L5 .
monitoring the DSM driver seat control switch input
status PIDs.
Do the PID values agree with the switch positions?
L5 CHECK THE SEAT CONTROL SWITCH
Yes
Remove the seat control switch. Refer to Seat Control GO to L6 .
Switch - Front in this section.
Check the seat control switch. No
INSTALL a new seat control switch.
Refer to Wiring Diagrams Cell 149 , Component REFER to Seat Control Switch - Front in
Testing for component testing. this section. CLEAR the DTCs. REPEAT
Is the seat control switch OK? the self-test.
L6 CHECK FOR VOLTAGE TO THE SEAT
CONTROL SWITCH
Yes
Ignition OFF. GO to L7 .
General Procedures portion of Section 501-20B . VERIFY SJB fuse 12 (7.5A) is OK. If
Disconnect: Driver Seat Safety Belt Buckle OK, REPAIR the circuit. If not OK,
Pretensioner C3049. REFER to the Wiring Diagrams manual
Disconnect: Driver Seat Side Air Bag C3051. to identify possible causes of the circuit
WARNING: Make sure no one is in the vehicle short. TEST the system for normal
and there is nothing blocking or placed in front of operation. CLEAR the DTCs. REPEAT
any air bag module when the battery is connected. the self-test.
Failure to follow these instructions may result in
serious personal injury in the event of an DISCONNECT the battery ground cable.

406- DOES
accidental deployment. CONNECT driver safety belt buckle

Connect the battery ground cable. Refer to Section pretensioner C3049.
414-01 .
Measure the voltage between seat control switch CONNECT driver seat side air bag
C3016-5, circuit SBP12 (GN/RD), harness side and module C3051.
ground.
501-20B .

L7 CHECK THE SEAT CONTROL SWITCH
Yes
Measure the resistance between seat control switch GO to L8 .
C3016-3, circuit GD133 (BK), harness side and
ground. No

pretensioner C3049.

module C3051.
501-20B .
L8 CHECK THE CIRCUITS BETWEEN THE SEAT
CONTROL SWITCH AND DSM FOR A SHORT TO
VOLTAGE
Yes
Disconnect: DSM C341B. REPAIR the circuit(s). CLEAR the
Ignition ON. DTCs. REPEAT the self-test.
Measure the voltage between seat control switch
C3016, harness side and ground using the following DISCONNECT the battery ground cable.
chart: CONNECT driver safety belt buckle
pretensioner C3049.

module C3051.
Connector Circuit
C3016-9 CPS28 (GN) REPOWER the SRS . REFER to Section
501-20B .
C3016-4 CPS23 (GN/VT)
C3016-2 CPS25 (WH/VT) No
C3016-6 CPS24 (GY) GO to L9 .

407- DOES
C3016-12 CPS26 (YE/BU)

C3016-1 CPS27 (BU/BN)
C3016-11 CPS29 (WH/BN)
C3016-8 CPS30 (VT/BN)
Is voltage present on any circuit?

CONTROL SWITCH AND DSM FOR A SHORT TO
GROUND
Yes
Ignition OFF. REPAIR the circuit(s). CLEAR the
Measure the resistance between seat control switch DTCs. REPEAT the self-test.
C3016 pins, harness side and ground using the
following chart: DISCONNECT the battery ground cable.
pretensioner C3049.

Connector Circuit module C3051.
C3016-9 CPS28 (GN)
C3016-4 CPS23 (GN/VT) 501-20B .
C3016-2 CPS25 (WH/VT)
C3016-6 CPS24 (GY) No
C3016-12 CPS26 (YE/BU) GO to L10 .
C3016-1 CPS27 (BU/BN)
C3016-11 CPS29 (WH/BN)
C3016-8 CPS30 (VT/BN)

CONTROL SWITCH AND DSM FOR AN OPEN

408- DOES
Measure the resistance between seat control switch Yes

C3016, harness side and DSM C341B, harness side INSTALL a new DSM . REFER to
using the following chart: Driver Seat Module (DSM) in this
section. CLEAR the DTCs. REPEAT the
self-test.

Seat Control Switch DSM CONNECT driver safety belt buckle
Connector Circuit Connector pretensioner C3049.
C3016-9 CPS28 (GN) C341B-15
C3016-4 CPS23 C341B-16 module C3051.
(GN/VT)
C3016-2 CPS25 C341B-18 REPOWER the SRS . REFER to Section
(WH/VT) 501-20B .
C3016-6 CPS24 (GY) C341B-6
C3016-12 CPS26 C341B-5 No
(YE/BU) REPAIR the circuit(s). CLEAR the
C3016-1 CPS27 C341B-17
(BU/BN) DISCONNECT the battery ground cable.
C3016-11 CPS29 C341B-19 CONNECT driver safety belt buckle
(WH/BN) pretensioner C3049.
C3016-8 CPS30 C341B-7
(VT/BN) CONNECT driver seat side air bag
module C3051.

501-20B .

L11 CHECK THE DSM FOR CORRECT OUTPUTS
USING A SCAN TOOL AND DSM ACTIVE
COMMANDS
Yes
Enter the following diagnostic mode on the scan tool: The fault is intermittent. CHECK the
DataLogger - DSM - PIDs. electrical connectors for corrosion, poor
Front Motor Up (FRONT_UP) pin contact or pushed out pins,
Front Motor Down (FRONT_DWN) particularly the pins and terminaf
Rear Motor Up (REAR_UP) electrical connectors that were
Rear Motor Down (REAR_DWN) disconnected. Do not install any new
Horizontal Motor Forward (HORZ_FWD) components at this time. Components
Horizontal Motor Backward (HORZ_BWD) should only be installed when directed
Recline Motor Forward (RECL_FWD) to do so in the pinpoint test. REPAIR
Recline Motor Backward (RECL_BWD) any intermittent wiring, terminal or
Toggle the DSM active commands ON and OFF connector concerns found. CLEAR the
while monitoring the seat movement. DTCs. REPEAT the self-test.
Does the driver seat operate correctly using the
active commands? DISCONNECT the battery ground cable.

409- DOES

pretensioner C3049.

module C3051.

501-20B .
No
If no seat movement, GO to L12 .
If no front vertical seat movement, GO to

L22 .
If no rear vertical seat movement, GO to

L25 .
If no horizontal seat movement, GO to

L28 .
If no recline seat movement, GO to L31 .

L12 CHECK FOR VOLTAGE TO THE DSM
Yes
Ignition OFF. GO to L13 .
General Procedures portion of Section 501-20B . VERIFY SJB fuses 2 (15A) and Battery
Disconnect: Driver seat safety belt buckle Junction Box (BJB) 74 (30A) are OK. If
pretensioner C3049. OK, REPAIR the circuit(s). If not OK,
Disconnect: Driver Seat Side Air Bag C3051. REFER to the Wiring Diagrams manual
Disconnect: DSM C341A. to identify possible causes of the circuit
Disconnect: DSM C341B. short. CLEAR the DTCs. REPEAT the
WARNING: Make sure no one is in the vehicle self-test.
any air bag module when the battery is connected. DISCONNECT the battery ground cable.
Failure to follow these instructions may result in CONNECT driver safety belt buckle
serious personal injury in the event of an pretensioner C3049.
Connect the battery ground cable. Refer to Section CONNECT driver seat side air bag
414-01 . module C3051.
Measure the voltage between:
DSM C341A-1, circuit SBP02 (YE/RD), REPOWER the SRS . REFER to Section
harness side and ground. 501-20B .
DSM C341B-1, circuit SBB74 (YE/RD),

410- DOES

L13 CHECK THE DSM GROUND CIRCUITS FOR AN
OPEN
Yes
Measure the resistance between: GO to L14 .
DSM C341A-2, circuit GD143 (BK/VT),
DSM C341B-24, circuit GD133 (BK), REPAIR the circuit(s). CLEAR the
harness side and ground. DTCs. REPEAT the self-test.

pretensioner C3049.

module C3051.

501-20B .
L14 CHECK THE FRONT HEIGHT MOTOR AND
Yes
DSM C341B-23, circuit CPS03 (VT/GY),
DSM C341B-11, circuit CPS02 (GY/YE), GO to L15 .

L15 CHECK THE FRONT HEIGHT MOTOR
Yes
Disconnect: Power Seat Front Height Motor C382. INSTALL a new driver seat track
Measure the resistance between: assembly. REFER to Seat Track - Power
DSM C341B-23, circuit CPS03 (VT/GY), in this section. CLEAR the DTCs.
harness side and ground. REPEAT the self-test.
DSM C341B-11, circuit CPS02 (GY/YE),
harness side and ground. DISCONNECT the battery ground cable.

411- DOES
pretensioner C3049.

module C3051.

501-20B .
No
pretensioner C3049.

module C3051.

501-20B .
L16 CHECK THE REAR HEIGHT MOTOR AND
Yes
DSM C341B-22, circuit CPS05 (BU/WH),
DSM C341B-10, circuit CPS04 (YE/OG), GO to L17 .

L17 CHECK THE REAR HEIGHT MOTOR
Yes
Disconnect: Power Seat Rear Height Motor C363. INSTALL a new driver seat track
DSM C341B-22, circuit CPS05 (BU/WH), in this section. CLEAR the DTCs.
DSM C341B-10, circuit CPS04 (YE/OG),
pretensioner C3049.

module C3051.

501-20B .

412- DOES
Are the resistances greater than 10,000 ohms? No

REPAIR the circuit(s). CLEAR the

pretensioner C3049.

module C3051.

501-20B .
L18 CHECK THE HORIZONTAL MOTOR AND
Yes
DSM C341B-9, circuit CPS06 (GN/WH),
DSM C341B-12, circuit CPS01 (GN/BU), GO to L19 .

L19 CHECK THE HORIZONTAL MOTOR CIRCUITS
Yes
Disconnect: Power Seat Horizontal Motor C362. INSTALL a new driver seat track
DSM C341B-9, circuit CPS06 (GN/WH), in this section. CLEAR the DTCs.
DSM C341B-12, circuit CPS01 (GN/BU),
pretensioner C3049.

module C3051.

501-20B .
No

413- DOES

pretensioner C3049.

module C3051.
SRS . REFER to Section 501-20B .
L20 CHECK THE RECLINER MOTOR AND
Yes
Measure the resistance between: INSTALL a new DSM . REFER to
DSM C341B-13, circuit CPS07 (GY/BN), Driver Seat Module (DSM) in this
harness side and ground. section. CLEAR the DTCs. REPEAT the
DSM C341B-21, circuit CPS08 (VT/OG), self-test.
pretensioner C3049.

module C3051.

501-20B .
No
GO to L21 .
L21 CHECK THE RECLINER MOTOR CIRCUITS
Yes
Disconnect: Driver Power Seat Recliner Motor INSTALL a new driver seat recliner
C3187. motor. CLEAR the DTCs. REPEAT the
Measure the resistance between: self-test.
DSM 341B-13, circuit CPS07 (GY/BN),
DSM C341B-21, circuit CPS08 (VT/OG), CONNECT driver safety belt buckle
harness side and ground. pretensioner C3049.

module C3051.

501-20B .
No

pretensioner C3049.

module C3051.

414- DOES

501-20B .
L22 CHECK THE FRONT HEIGHT MOTOR FOR
CORRECT OPERATION USING ACTIVE
COMMANDS
Yes
Depower the SRS . Refer to Supplemental Restraint assembly. REFER to Seat Track - Power
System (SRS) Depowering and Repowering in the in this section. CLEAR the DTCs.
General Procedures portion of Section 501-20B . REPEAT the self-test.
Disconnect: Driver Seat Safety Belt Buckle
Pretensioner C3049. DISCONNECT the battery ground cable.
Disconnect: Driver Seat Side Air Bag C3051. CONNECT driver safety belt buckle
Disconnect: Power Seat Front Height Motor C382. pretensioner C3049.
WARNING: Make sure no one is in the vehicle
and there is nothing blocking or placed in front of CONNECT driver seat side air bag
any air bag module when the battery is connected. module C3051.
serious personal injury in the event of an REPOWER the . REFER to Section
accidental deployment. 501-20B .
Connect the battery ground cable. Refer to Section
414-01 . No
Ignition ON. GO to L23 .
Front Motor Up (FRONT_UP)
Front Motor Down (FRONT_DWN)
Measure the voltage between power seat front height
motor C382-3, circuit CPS03 (VT/GY) and C382-4,
circuit CPS02 (GY/YE), harness side while using the
scan tool to operate DSM active commands front
motor up and front motor down, ON and OFF.
Is the voltage greater than 10 volts when

commanded ON in both directions and no voltage
present when commanded OFF?

415- DOES
Ignition OFF. Yes

DSM C341B-23, circuit CPS03 (VT/GY), DISCONNECT the battery ground cable.
harness side and ground. CONNECT driver safety belt buckle
DSM C341B-11, circuit CPS02 (GY/YE), pretensioner C3049.
module C3051.

501-20B .
No
GO to L24 .
Yes
Ignition OFF. INSTALL a new DSM . REFER to
Measure the resistance between: Driver Seat Module (DSM) in this
DSM C341B-23, circuit CPS03 (VT/GY), section. CLEAR the DTCs. REPEAT the
harness side and front height motor C382-3, self-test.
circuit CPS03 (VT/GY), harness side.
DSM C341B-11, circuit CPS02 (GY/YE), DISCONNECT the battery ground cable.
harness side and front height motor C382-4, CONNECT driver safety belt buckle
circuit CPS02 (GY/YE), harness side. pretensioner C3049.

module C3051.

501-20B .
No

pretensioner C3049.

module C3051.

501-20B .
L25 CHECK THE REAR HEIGHT MOTOR FOR
COMMANDS

416- DOES
Ignition OFF. Yes

Depower the SRS . Refer to Supplemental Restraint INSTALL a new driver seat track
System (SRS) Depowering and Repowering in the assembly. REFER to Seat Track - Power
General Procedures portion of Section 501-20B . in this section. CLEAR the DTCs.
Disconnect: Driver Seat Safety Belt Buckle REPEAT the self-test.
Pretensioner C3049.
Disconnect: Driver Seat Side Air Bag C3051. DISCONNECT the battery ground cable.
Disconnect: Power Seat Rear Height Motor C363. CONNECT driver safety belt buckle
WARNING: Make sure no one is in the vehicle pretensioner C3049.
any air bag module when the battery is connected. CONNECT driver seat side air bag
Failure to follow these instructions may result in module C3051.
serious personal injury in the event of an
accidental deployment. REPOWER the SRS . REFER to Section
Connect the battery ground cable. Refer to Section 501-20B .
414-01 .
Ignition ON. No
Rear Motor Up (REAR_UP)
Rear Motor Down (REAR_DWN)
Measure the voltage between power seat rear height
motor C363-3, circuit CPS05 (BU/WH), harness side
and C363-4, circuit CPS04 (YE/OG), harness side
while using the scan tool to operate DSM active
commands rear motor up and rear motor down, ON
and OFF.
Is the voltage greater than 10 volts when command

ON in both directions and no voltage present when
commanded OFF?
Yes
Disconnect: DSM C341B. DTCs. REPEAT the self-test.
Ignition ON.
Measure the voltage between: DISCONNECT the battery ground cable.
DSM C341B-22, circuit CPS05 (BU/WH), CONNECT driver safety belt buckle
DSM C341B-10, circu CPS04 (YE/OG),
harness side and ground. CONNECT driver seat side air bag
module C3051.

417- DOES
501-20B .
No
GO to L27 .

Yes
DSM C341B-22, circuit CPS05 (BU/WH), section. CLEAR the DTCs. REPEAT the
harness side and rear height motor C363-3, self-test.
circuit CPS05 (BU/WH), harness side.
DSM C341B-10, circuit CPS04 (YE/OG), DISCONNECT the battery ground cable.
harness side and rear height motor C363-4, CONNECT driver safety belt buckle
circuit CPS04 (YE/OG), harness side. pretensioner C3049.

module C3051.

501-20B .
No

pretensioner C3049.

module C3051.

501-20B .
L28 CHECK THE HORIZONTAL MOTOR FOR
COMMANDS
Yes
Depower the SRS . Refer to Supplemental Restraint assembly. REFER to Seat Track - Power
System (SRS) Depowering and Repowering in the in this section. CLEAR the DTCs.
General Procedures portion of Section 501-20B . REPEAT the self-test.
Disconnect: Driver Seat Safety Belt Buckle
Pretensioner C3049. DISCONNECT the battery ground cable.
Disconnect: Driver Seat Side Air Bag C3051. CONNECT driver safety belt buckle
Disconnect: Power Seat Horizontal Motor C362. pretensioner C3049.
WARNING: Make sure no one is in the vehicle
and there is nothing blocking or placed in front of CONNECT driver seat side air bag
any air bag module when the battery is connected. module C3051.

418- DOES

serious personal injury in the event of an REPOWER the SRS . REFER to Section
accidental deployment. 501-20B .
Connect the battery ground cable. Refer to Section
414-01 . No
Horizontal Motor Forward (HORZ_FWD)
Horizontal Motor Backward (HORZ_BWD)
Measure the voltage between horizontal motor
C362-3, circuit CPS06 (GN/WH) and C362-4, circuit
CPS01 (GN/BU), harness side while using the scan
tool to operate DSM active commands horizontal
motor forward and horizontal motor backward, ON
and OFF.
Is the voltage greater than 10 volten command ON

in both directions and no voltage present when
commanded OFF?
Yes
Measure the voltage tween:
DSM C341B-9, circuit CPS06 (GN/WH), DISCONNECT the battery ground cable.
harness side and ground. CONNECT driver safety belt buckle
DSM C341B-12, circuit CPS01 (GN/BU), pretensioner C3049.
module C3051.

501-20B .
No
GO to L30 .
FOR AN OPEN

419- DOES
Ignition OFF. Yes

Measure the resistance between: INSTALL a new DSM . REFER to
DSM C341B-9, circuit CPS06 (GN/WH), Driver Seat Module (DSM) in this
harness side and horizontal motor C362-3, section. CLEAR the DTCs. REPEAT the
circuit CPS06 (GN/WH), harness side. self-test.
DSM C341B-12, circuit CPS01 (GN/BU),
harness side and horizontal motor C362-4, DISCONNECT the battery ground cable.
circuit CPS01 (GN/BU), harness side. CONNECT driver safety belt buckle
pretensioner C3049.

module C3051.

501-20B .
No

pretensioner C3049.

module C3051.

501-20B .
L31 CHECK THE RECLINER MOTOR FOR
COMMANDS
Yes
Ignition OFF. INSTALL a new driver seat recliner
Depower the SRS . Refer to Supplemental Restraint motor. CLEAR the DTCs. REPEAT the
System (SRS) Depowering and Repowering in the self-test.
General Procedures portion of Section 501-20B .
Disconnect: Driver Seat Safety Belt Buckle DISCONNECT the battery ground cable.
Pretensioner C3049. CONNECT driver safety belt buckle
Disconnect: Driver Seat Side Air Bag C3051. pretensioner C3049.
Disconnect: Driver Seat Power Recliner Motor
C3187. CONNECT driver seat side air bag
WARNING: Make sure no one is in the vehicle module C3051.
any air bag module when the battery is connected. REPOWER the SRS . REFER to Section
Failure to follow these instructions may result in 501-20B .
serious personal injury in the event of an
accidental deployment. No
Connect the battery ground cable. Refer to Section GO to L32 .
414-01 .
Ignition ON.
Recline Motor Forward (RECL_FWD)

420- DOES
Recline Motor Backward (RECL_BWD)

Measure the voltage between power recliner motor
C3187-2, circuit CPS07 (GY/BN) and C3187-1,
circuit CPS08 (VT/OG), harness side while using the
scan tool to operate the DSM active commands
recline motor forward recline motor backward, ON
and OFF.
Is the voltage greater than 10 volts when command

ON in both directions and no voltage present when
commanded OFF?
Yes
Disconnect: DSM C341B. DTCs. REPEAT the self-test.
Ignition ON.
Measure the voltage between: DISCONNECT the battery ground cable.
DSM C341B-13, circuit CPS07 (GY/BN), CONNECT driver safety belt buckle
DSM C341B-21, circuit CPS08 (VT/OG),
harness side and ground. CONNECT driver seat side air bag
module C3051.

501-20B .
No
GO to L33 .

FOR AN OPEN
Yes
DSM C341B-13, circuit CPS07 (GY/BN), section. CLEAR the DTCs. REPEAT the
harness side and recliner motor C3187-2, self-test.
circuit CPS07 (GY/BN), harness side.
DSM C341B-21, circuit CPS08 (VT/OG), DISCONNECT the battery ground cable.
harness side and recliner motor C3187-1, CONNECT driver safety belt buckle
circuit CPS08 (VT/OG), harness side. pretensioner C3049.

421- DOES
module C3051.

501-20B .
No

pretensioner C3049.

module C3051.

501-20B .
Pinpoint Test M: The Memory Seat Does Not Operate Correctly - Does Not Operate Using the Memory
SET Switch
Refer to Wiring Diagrams Cell 123 , Memory Seats for schematic and connector information.
Normal Operation
The driver seat control switch is powered by battery voltage on circuit SBP12 (GN/RD) and is supplied
ground on circuit GD133 (BK). When pressed, the seat control switch supplies voltage and ground to the
applicable Driver Seat Module (DSM) inputs. The DSM then supplies voltage and ground to the appropriate
power seat track motor or power recline motor based on the inputs received from the seat control switch.
When pressed in the opposite direction, the seat control switch reverses the polarity to the DSM inputs, and
the DSM likewise reverses polarity of the appropriate power seat track motor or power recliner motor circuits
causing the seat or backrest to move in the opposite direction. There are 3 power seat track motors that
combine to move the seat horizontally (forward/rearward) and vertically (front up/down and rear up/down).
The seat backrest power recliner mechanism uses a single motor to move the seat backrest forward and
rearward.
Battery voltage is also supplied to the DSM on circuits SBP02 (YE/RD) and SBB74 (YE/RD). Ground is
supplied to the DSM on circuits GD133 (BK) and GD143 (BK/VT).
Each motor in the memory power seat track and power recliner mechanism contains a Hall-effect position
sensor. The DSM supplies a shared signal feed circuit to each position sensor. Each position sensor sends a
signal pulse back to the DSM to monitor the position of the power seat and seat backrest. The DSM uses this
information to return the seat to a stored pre-programmed position when pressing the memory SET switch or a
Remote Keyless Entry (RKE) transmitter. For information on programming memory positions or recalling a
stored memory position, refer to Memory Position Programming in this section.
The following pinpoint test diagnoses a memory seat that does not operate correctly using the memory SET
switch. If the memory seat does not move in all directions using the seat control switch, GO to Pinpoint Test
L.


If a programming error is detected, the DTC is set.
B1342 - ECU is
Faulted
If a short to ground is sensed on the switch input circuit during the DSM
B1534 - Memory 1 self-test, the DTC is set. If activity is sensed on the input circuit for greater
Switch Circuit Short to than 2 minutes, the DTC is set as continuous. With the DTC set, any input
Ground signal on the circuit is ignored.
B1538 - Memory 2
Ground
During self-test the DSM attempts to operate the seat track motors and uses
B1663 - Seat Driver the motor's position sensor to monitor movement. If no motor movement is
Front Up/Down Motor sensed, a DTC is set. The DSM will retry motor operation on the next
Stalled activation of the seat control switch. If no movement continues to be
B1664 - Seat Driver monitored after 250 milliseconds, the DSM disables the output.
Rear Up/Down Motor
Stalled
B1665 - Seat Driver
Forward/Backward
Motor Stalled
During self-test the DSM attempts to operate the recliner motor and uses the
B1666 - Seat Driver recliner motor position sensor to monitor movement. If no motor movement
Recline Motor Stalled is sensed, the DTC is set. The DSM will retry motor operation on the next
activation of the seat control switch. If no motor movement is still
monitored after 250 milliseconds, the DSM disables the output.
If a short to voltage condition is present on the affected motor's position
B1952 - Seat Rear sensor (Hall effect) feedback circuit, the DTC is set. After a DTC is set, a
Up/Down Position memory recall is not possible but the seat control switch can operate the
Feedback Circuit Short associated motor in one second increments.
to Battery
B1956 - Seat Front
Up/Down Position
Feedback Circuit Short
to Battery
B1960 - Seat Recline
Forward/Backward
Position Feedback
B1964 - Seat
Horizontal
Forward/Rearward
Position Feedback
If a short to ground or open condition is present on the affected motor's
B1953 - Seat Rear position sensor (Hall effect) feedback circuit, the DTC is set. Af, a memory
Up/Down Position recall is not possible but the seat control switch can operate the associated
Feedback Circuit Short motor in one second increments.
to Ground
B1957 - Seat Front
Up/Down Position
Feedback Circuit Short
to Ground

B1961 - Seat Recline

Forward/Backward
Position Feedback
Circuit Short to Ground
B1965 - Seat
Horizontal
Forward/Rearward
Position Feedback

Memory SET switch
Missing status information - Medium Speed Controller Area Network (MS-CAN) communication bus
messages:
ignition status
gear selector position
Remote Keyless Entry (RKE) transmitter
Memory power seat track
Recliner mechanism
Driver Seat Module (DSM)
PINPOINT TEST M: THE MEMORY SEAT DOES NOT OPERATE CORRECTLY - DOES NOT OPERATE USING THE
MEMORY SET SWITCH
NOTE: Verify the PID(s) states agree with the ignition and transmission gear selector in all positions before
proceeding with memory seat diagnosis.
M1 CHECK THE TRANSMISSION GEAR SELECTOR

TRANSMISSION RANGE (TR) PID STATES
Yes
Enter the following diagnostic mode on the scan tool: GO to M2 .
DataLogger - TCM - PID: TR.
Operate the transmission gear selector in all positions while No
monitoring the TCM PID TR states. To diagnose a transmission gear
Do the PID states agree with the selected positions? selector (PRNDL) status concern,
M2 CHECK THE IGNITION SWITCH PIDs
PINPOINT TEST M: THE MEMORY SEAT DOES NOT OPERATE CORRECTLY - DOES NOT OPERATE
424 U
Enter the following diagnostic mode on the scan tool: Yes

DataLogger - IC - PIDs. GO to M3 .
ACC Position (IGN_A) No

Ignition Switch - Off/Unlock Position (IGN_O/U) To diagnose an ignition switch
Ignition Switch - Run Position (IGN_R) status concern, REFER to Section
Start (Position 3) (IGN_S) 211-05 .
Cycle the ignition in all positions while monitoring the PIDs.
Do the PIDs agree with the selected positions?
M3 RETRIEVE THE DSM DTCs
Yes
Operate the memory seat, memory mirrors, adjustable If DTCs B1952, B1956, B1960
memory pedals (if equipped) and adjustable memory and B1964 are all retrieved, GO to
steering column (if equipped) in all directions through the M10 .
full range of travel.
Place the memory seat, memory mirrors, adjustable memory If DTCs B1953, B1957, B1961
pedals (if equipped) and adjustable memory steering column and B1965 are all retrieved, GO to
(if equipped) in central travel positions. M10 .
Enter the following diagnostic mode on the scan tool: Self
Test - DSM . If DTC B1534, GO to M5 .
If DTC B1538, GO to M5 .
If DTC B1342, INSTALL a new

DSM . REFER to Driver Seat
Module (DSM) in this section.
self-test.
For any other DSM DTCs, REFER
425 U
to the Driver Seat Module (DSM)

DTC Chart.
No
GO to M4 .
M4 MONITOR THE DSM PIDs AND CHECK THE DSM
FOR CORRECT MEMORY SET SWITCH INPUTS
Yes
Enter the following diagnostic mode on the scan tool: GO to M10 .
Memory 1 recall switch status (MEM_1) No
Memory 2 recall switch status (MEM_2) GO to M5 .
Monitor the DSM PIDs while activating memory SET
switch buttons recall 1 and recall 2.
Do the PID values agree with the switch button
positions?
>
M5 CHECK THE MEMORY SET SWITCH
Yes
Ignition OFF. GO to M6 .
(SRS) Depowering and Repowering in the General No
Procedures portion of Section 501-20B . INSTALL a new memory SET
Disconnect: Memory SET Switch C3246. switch. REFER to Memory Set
Using the following table to check the memory SET switch, Switch in this section.
measure the resistance between the memory SET switch
pins, component side, while pressing the indicated switch REPOWER the SRS . REFER to
buttons and compare the results to the table. Section 501-20B .

self-test.
Switch Button Pins Ohms

Memory Switch 1 2 and 3 Less
than 20
Memory Switch 2 2 and 7 Less
than 20
Is the resistance less than 20 ohms with the switch

buttons depressed and greater than 10,000 ohms with the
switch buttons released?
M6 CHECK THE MEMORY SET SWITCH GROUND
CIRCUIT FOR AN OPEN
426 U
Ignition OFF. Yes

Depower the SRS . Refer to Supplemental Restraint System GO to M7 .
(SRS) Depowering and Repowering in the General
Procedures portion of Section 501-20B . No
Disconnect: Driver Seat Safety Belt Buckle Pretensioner REPAIR the circuit. CLEAR the
C3049. DTCs. REPEAT the self-test.
Disconnect: Driver Seat Side Air Bag C3051.
WARNING: Make sure no one is in the vehicle and DISCONNECT the battery ground
there is nothing blocking or placed in front of any air bag cable. CONNECT driver safety
module when the battery is connected. Failure to follow belt buckle pretensioner C3049.
the event of an accidental deployment. CONNECT driver seat side air bag
Connect the battery ground cable. Refer to Section 414-01 . module C3051.
Measure the resistance between memory SET switch
C3246-2, circuit GD133 (BK), harness side and ground. REPOWER the SRS . REFER to
Section 501-20B .

M7 CHECK THE MEMORY SET SWITCH CIRCUITS FOR
A SHORT TO VOLTAGE
Yes
Disconnect: DSM C341C. REPAIR the circuit(s). CLEAR
Ignition ON. the DTCs. REPEAT the self-test.
Measure the voltage between the following memory SET
switch C3246 pins, harness side and ground: DISCONNECT the battery ground

Connector Circuit module C3051.
C3246-3 CPS15 (VT/WH)
C3246-7 CPS16 (YE) Section 501-20B .
No
GO to M8 .

A SHORT TO GROUND
427 U
Ignition OFF. Yes

Measure the resistance between the following memory SET GO to M9 .
switch C3246 pins, harness side and ground:
No
the DTCs. REPEAT the self-test.
Connector Circuit DISCONNECT the battery ground

C3246-3 CPS15 (VT/WH) cable. CONNECT driver safety
C3246-7 CPS16 (YE)
module C3051.

Section 501-20B .

AN OPEN
Yes
Measure the resistance between the following memory SET INSTALL a new DSM . REFER to
switch C3246 pins and DSM C341C pins: Driver Seat Module (DSM) in this

Memory SET Switch DSM cable. CONNECT driver safety
Connector Circuit Connector belt buckle pretensioner C3049.
C3246-3 CPS15 C341C-16
(VT/WH) CONNECT driver seat side air bag
module C3051.
C3246-7 CPS16 (YE) C341C-17
Section 501-20B .
No

Are the resistances less than 5 ohms? belt buckle pretensioner C3049.

module C3051.

Section 501-20B .
M10 MONITOR THE DSM PIDs
428 U

DataLogger - DSM - PIDs. INSTALL a new DSM . REFER to
Driver Power Seat Front Up/Down Sense Driver Seat Module (DSM) in this
(SFNT_MT) section. CLEAR the DTCs.
Driver Power Seat Forward/Backward Sense REPEAT the self-test.
(SFWD_MT)
Driver Power Seat Recline Sense (SRCL_MT) No
Driver Power Seat Rear Up/Down Sense If front up/down position sensor
(SREARMT) PID value indicates not present,
Using the switches, operate the memory seat in all directions GO to M11 .
through the full range of travel while monitoring the PIDs.
Does each PID indicate the sensor is operational If rear up/down position sensor
throughout each associated motor's full range of travel? PID value indicates not pre, GO to
M14 .
If forward/rearward position
sensor PID value indicates not
present, GO to M17 .
If recline position sensor PID

value indicates not present, GO to
M20 .
M11 CHECK THE FRONT HEIGHT POSITION SENSOR
Yes
Ignition OFF. REPAIR the circuit(s). CLEAR
Depower the SRS . Refer to Supplemental Restraint System the DTCs. REPEAT the self-test.
Procedures portion of Section 501-20B . DISCONNECT the battery ground
Disconnect: Driver Seat Safety Belt Buckle Pretensioner cable. CONNECT driver safety
C3049. belt buckle pretensioner C3049.
Disconnect: DSM C341B. CONNECT driver seat side air bag
Disconnect: Driver Seat Front Height Motor C382. module C3051.
there is nothing blocking or placed in front of any air bag REPOWER the SRS . REFER to
module when the battery is connected. Failure to follow Section 501-20B .
the event of an accidental deployment. No
Connect the battery ground cable. Refer to Section 414-01 . GO to M12 .
Ignition ON.
driver seat front height motor C382-6, circuit RPS13
(GN/OG), harness side and ground.
driver seat front height motor C382-5, circuit VPS10
(BU/GN), harness side and ground.
429 U

Yes
Measure the resistance between:
driver seat front height motor C382-6, circuit RPS13 No
(GN/OG), harness side and ground. REPAIR the circuit(s). CLEAR
driver seat front height motor C382-5, driver seat the DTCs. REPEAT the self-test.
horizontal motor, circuit VPS10 (BU/GN), harness
side and ground. DISCONNECT the battery ground

module C3051.

Section 501-20B .
Yes
Measure the resistance between: INSTALL a new driver seat track
driver seat front height motor C382-6, circuit RPS13 assembly. REFER to Seat Track -
(GN/OG), harness side and DSM C341B-8, circuit Power in this section. CLEAR the
RPS13 (GN/OG), harness side. DTCs. REPEAT the self-test.
driver seat front height motor C382-5, circuit VPS10
(BU/GN), harness side and DSM C341B-4, circuit DISCONNECT the battery ground
VPS10 (BU/GN), harness side. cable. CONNECT driver safety

module C3051.

Section 501-20B .
No

430 U

module C3051.

Section 501-20B .
M14 CHECK THE REAR HEIGHT POSITION SENSOR
Yes
Disconnect: Driver Seat Rear Height Motor C363. module C3051.
Ignition ON.
driver seat rear height motor C363-6, circuit RPS13
driver seat rear height motor C363-5, circuit VPS11
(GN/BN), harness side and ground.

Yes
driver seat rear height motor C363-6, circuit RPS13 No
driver seat rear height motor C363-5, circuit VPS11 the DTCs. REPEAT the self-test.
(GN/BN), harness side and ground.

module C3051.
431 U

Section 501-20B .

Yes
driver seat rear height motor C363-6, circuit RPS13 assembly. REFER to Seat Track -
(GN/OG), harness side and DSM C341B-8, circuit Pow in this section. CLEAR the
driver seat rear height motor C363-5, circuit VPS11
(GN/BN), harness side and DSM C341B-3, circuit DISCONNECT the battery ground
VPS11 (GN/BN), harness side. cable. CONNECT driver safety

module C3051.

Section 501-20B .
No
REPAIR the circuit(s) in question.
self-test.


module C3051.

Section 501-20B .
M17 CHECK THE HORIZONTAL POSITION SENSOR
Yes
Disconnect: Driver Seat Horizontal Motor C362. module C3051.
432 U

Ignition ON.
driver seat horizontal motor C362-6, circuit RPS13
driver seat horizontal motor C362-5, circuit VPS09
(BN/BU), harness side and ground.

Yes
driver seat horizontal motor C362-6, circuit RPS13 No
driver seat horizontal motor C362-5, circuit VPS09 the DTCs. REPEAT the self-test.

module C3051.

Section 501-20B .
Yes
driver seat horizontal motor C362-6, circuit RPS13 assembly. REFER to Seat Track -
(GN/OG), harness side and DSM C341B-8, circuit Power in this section. CLEAR the
driver seat horizontal motor C362-5, circuit VPS09
(BN/BU), harness side and DSM C341B-14, circuit DISCONNECT the battery ground
VPS09 (BN/BU), harness side. cable. CONNECT driver safety

module C3051.
433 U

Section 501-20B .
No
REPAIR the circuit(s).LEAR the

module C3051.

Section 501-20B .
M20 CHECK THE RECLINER POSITION SENSOR
Yes
Disconnect: Driver Seat Recliner Motor C3187. module C3051.
Ignition ON.
memory seat recliner motor C3187-3, circuit RPS13
memory seat recliner motor C3187-4, circuit VPS12
(GY/OG), harness side and ground.

434 U
Ignition OFF. Yes

Measure the resistance between: GO to M22 .
memory seat recliner motor C3187-3, circuit RPS13
(GN/OG), harness side and ground. No
memory seat recliner motor C3187-4, circuit VPS12 REPAIR the circuit(s). CLEAR
(GY/OG), harness side and ground. the DTCs. REPEAT the self-test.


module C3051.

Section 501-20B .
Yes
Measure the resistance between: INSTALL a new driver seat
memory seat recliner motor C3187-3, circuit RPS13 recliner motor. CLEAR the DTCs.
(GN/OG), harness side and DSM C341B-8, circuit REPEAT the self-test.
RPS13 (GN/OG), harness side.
memory seat recliner motor C3187-4, circuit VPS12 DISCONNECT the battery ground
(GY/OG), harness side and DSM C341B-20, circuit cable. CONNECT driver safety
VPS12 (GY/OG), harness side. belt buckle pretensioner C3049.

module C3051.

Section 501-20B .
No


module C3051.

Section 501-20B .
Pinpoint Test N: Easy Exit/Easy Entry is Inoperative/Does Not Operate Correctly
Normal Operation
The Driver Seat Module (DSM) receives a key out command over the Medium Speed Controller Area
Network (MS-CAN) communication network and powers the driver seat rearward about 51 mm (2 in).

Easy entry/exit feature is not enabled
Missing status information - MS-CAN communication bus messages:
key-in-ignition warning switch status
gear selector position
Key-in-ignition warning switch
DSM
PINPOINT TEST N: EASY EXIT/EASY ENTRY IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
NOTE: The transmission gear selector must be in PARK and the driver seat must be at least 51 mm (2 in)
from its rear stopping point for the easy entry/exit feature to function.
NOTE: Make sure all memory seat DTC and symptom based faults are corrected before proceeding with easy
entry/exit diagnosis. Verify the PID(s) states agree with the ignition and transmission gear selector in all
positions before proceeding with easy entry/exit diagnosis.
Test Step Result / Acon to Take

N1 CHECK THE DRIVER POWER SEAT
OPERATION
Yes
Ignition ON. REFER to the Driver Seat Module (DSM)
Check the message center to verify the easy DTC Chart in this section.
entry/exit feature is turned on.
The easy entry/exit feature can be No
enabled/disabled using a scan tool in module If OFF, turn the easy entry/exit feature ON
programming. When enabled, the feature with the message center. REFER to the
becomes a user accessible item on the Owner's Literature or Section 413-01 .
message center allowing the user to turn the TEST the system for normal operation. If
feature on and off. Refer to the Owner's OK, INSTRUCT the customer on correct
Literature or Section 413-01 for information system operation.
on the message center.
Using the seat control switch, verify the driver If easy entry/exit is ON and the seat does
power seat operates fully forward and rearward. not move horizontally from the seat
Place the memory seat, memory mirrors, adjustable control switch, GO to Pinpoint Test L .
memory pedals (if equipped) and adjustable memory
steering column (if equipped) in central travel Otherwise, GO to N2 .
positions.
Enter the following diagnostic mode on the scan
tool: Self Test - DSM .
N2 CHECK THE TRANSMISSION GEAR
SELECTOR TRANSMISSION RANGE (TR) PID
STATES
PINPOINT TEST N: EASY EXIT/EASY ENTRY IS INOPERATIVE/DOES NOT OPERATE CORRECTLY

436
Enter the following diagnostic mode on the scan Yes

tool: DataLogger - TCM - PID: TR. GO to N3 .
Operate the transmission gear selector in all
positions while monitoring the TCM PID TR states. No
Do the PID states agree with the selected To diagnose a transmission gear selector
positions? (PRNDL) status concern, REFER to
Section 307-01 .
N3 CHECK THE IGNITION SWITCH POSITION
(IGN_SW) PID
Yes
Enter the following diagnostic mode on the scan INSTALL a new DSM . REFER to Driver
tool: DataLogger - SJB - PIDs. Seat Module (DSM) in this section.
Monitor the SJB PID IGN_SW with the key in and CLEAR the DTCs. REPEAT the self-test.
out of the ignition switch.
Does the PID agree with the key in and out of the No
ignition switch? To diagnose the key-in-tion warning
switch fault, REFER to Section 413-01 .
Pinpoint Test O: The Power Lumbar is Inoperative - Driver
Refer to Wiring Diagrams Cell 123 , Memory Seats for schematic and connector information.
Normal Operation
The seat control switch contains the lumbar button and when pressed, supplies battery voltage and ground to
the power lumbar motor on circuits CPS18 (BN/GN) and CPS19 (GY/VT) to move the lumbar assembly in
the desired direction.

Seat control swit
Power lumbar motor assembly
PINPOINT TEST O: THE POWER LUMBAR IS INOPERATIVE - DRIVER

O1 CHECK OTHER SEAT CONTROL SWITCH FEATURES FOR
CORRECT OPERATION
Yes
Operate the seat horizontally and vertically. GO to O2 .
Does the seat operate horizontally and vertically?
No

For seat with memory,

GO to Pinpoint Test L to
diagnose the inoperative
seat.
For seat without memory,

GO to Pinpoint Test to
seat.
O2 CHECK FOR VOLTAGE TO THE LUMBAR MOTOR
Yes
Ignition OFF. INSTALL a new power
Depower the SRS . Refer to Supplemental Restraint System (SRS) lumbar assembly. REFER
Depowering and Repowering in the General Procedures portion of to Lumbar Assembly in
Section 501-20B . this section. TEST the
Disconnect: Driver Seat Safety Belt Buckle Pretensioner C3049. system for normal
Disconnect: Driver Seat Side Air Bag C3051. operation.
Disconnect: Power Lumbar Motor C3215.
WARNING: Make sure no one is in the vehicle and there is DISCONNECT the
nothing blocking or placed in front of any air bag module when battery ground cable.
the battery is connected. Failure to follow these instructions may CONNECT driver safety
result in serious personal injury in the event of an accidental belt buckle pretensioner
deployment. C3049.
While toggling the power lumbar switch, measure the voltage CONNECT driver seat
between power lumbar motor C3215-B, circuit CPS18 (BN/GN), side air bag module
harness side and power lumbar motor C3215-A, circuit CPS19 C3051.
(GY/VT), harness side.
REPOWER the SRS .
REFER to Section
501-20B .
No
GO to O3 .
Is the voltage greater than 10 volts when the seat control switch is
operated in both directions and 0 volt in the rest position?
O3 CHECK THE LUMBAR MOTOR CIRCUITS FOR AN OPEN
Yes
Disconnect: Seat Control Switch C3016. INSTALL a new seat
Measure the resistance between: control switch. REFER to
seat control switch C3016-7, circuit CPS18 (BN/GN), Seat Control Switch -
harness side and power lumbar motor C3215-B, circuit Front in this section.
CPS18 (BN/GN), harness side. TEST the system for
seat control switch C3016-10, circuit CPS19 (GY/VT), normal operation.
harness side and power lumbar motor C3215-A, circuit
CPS19 (GY/VT), harness side. DISCONNECT the
battery ground cable.
CONNECT driver safety
belt buckle pretensioner
C3049.
PINPOINT TEST O: THE POWER LUMBAR IS INOPERATIVE - DRIVER 438

CONNECT driver seat

side air bag module
C3051.
REPOWER the SRS .

REFER to Section
501-20B .
No
TEST the system for
normal operation.
DISCONNECT the
CONNECT driver safety
belt buckle pretensioner
C3049.
CONNECT driver seat

side air bag module
C3051.
REPOWER the SRS .

REFER to Section
501-20B .
Pinpoint Test P: The Power Lumbar is Inoperative - Passenger
Normal Operation
The seat control switch contains the lumbar button and when pressed, supplies battery voltage and ground to
the power lumbar motor on circuits CPS18 (BN/GN) and CPS19 (GY/VT) to move the lumbar assemb in the
desired direction.

Seat control switch
Power lumbar motor assembly
PINPOINT TEST P: THE POWER LUMBAR IS INOPERATIVE - PASSENGER


P1 CHECK OTHER SEAT CONTROL SWITCH FEATURES FOR
CORRECT OPERATION
Yes
Operate the seat horizontally and vertically. GO to P2 .
Does the seat operate horizontally and vertically?
No
GO to Pinpoint Test J to
seat.
P2 CHECK FOR VOLTAGE TO THE LUMBAR MOTOR
Yes
Ignition OFF. INSTALL a new power
lumbar assembly. REFER
Depower the SRS . Refer to Supplemental Restraint System (SRS) to Lumbar Assembly in
Depowering and Repowering in the General Procedures portion of this section. TEST the
Section 501-20B . system for normal
Disconnect: Passenger Seat Safety Belt Buckle Pretensioner C3050. operation.
Disconnect: Power Lumbar Motor C3216. DISCONNECT the
WARNING: Make sure no one is in the vehicle and there is battery ground cable.
nothing blocking or placed in front of any air bag module when CONNECT passenger
the battery is connected. Failure to follow these instructions may safety belt buckle
result in serious personal injury in the event of an accidental pretensioner C3050.
deployment.
Connect the battery ground cable. Refer to Section 414-01 . CONNECT passenger
While toggling the power lumbar switch, measure the voltage seat side air bag module
between power lumbar motor C3216-B, circuit CPS18 (BN/GN), C3052.
harness side and power lumbar motor C3216-A, circuit CPS19
(GY/VT), harness side. REPOWER the SRS .
REFER to Section
501-20B .
No
GO to P3 .
Is the voltage greater than 10 volts when the seat control switch is
operated in both directions and 0 volt in the rest position?
P3 CHECK THE LUMBAR MOTOR CIRCUITS FOR AN OPEN
Yes
Disconnect: Passenger Seat Control Switch C3026. INSTALL a new seat
Measure the resistance between: control switch. REFER to
seat control switch C3026-7, circuit CPS20 (VT), harness Seat Control Switch -
side and power lumbar motor C3216-B, circuit CPS18 Front in this section.
(BN/GN), harness side. TEST the system for
seat control switch C3026-10, circuit CPS21 (WH/OG), normal operation.
harness side and power lumbar motor C3216-A, circuit
CPS19 (GY/VT), harness side. DISCONNECT the
PINPOINT TEST P: THE POWER LUMBAR IS INOPERATIVE - PASSENGER 440

CONNECT passenger
safety belt buckle
pretensioner C3050.
CONNECT passenger
seat side air bag module
C3052.
REPOWER the SRS .

REFER to Section
501-20B .
No
TEST the system for
normal operation.
DISCONNECT the
CONNECT passenger
safety belt buckle
pretensioner C3050.
CONNECT passenger
seat side air bag module
C3052.
REPOWER the SRS .

REFER to Section
501-20B .
Pinpoint Test Q: A Single Climate Controlled Seat is Inoperative - Switch Indicators May Or May Not
Illuminate
Refer to Wiring Diagrams Cell 119 , Climate Controlled Seats for schematic and connector information.
Normal Operation
The Dual Climate Controlled Seat Module (DCSM) is supplied voltage from Battery Junction Box (BJB) fuse
67 (40A) to C3265A pin E, circuits SBB08 (VT/RD) and C3265A pin F, circuit SBB08 (VT/RD). The DCSM
is supplied ground from C3265A pin M, circuit GD138 (BK/WH). Both voltage supply circuits are hot at all
times, but the climate controlled seat system only operates with the engine running. The system can be
operated with the ignition ON engine OFF by using a scan tool to bypass the climate controlled seat switches
on the HVAC module and when commanding a heat or cool mode operation in this manner will only operate
in 15-second intervals. Both voltage supply circuits are spliced together internal to the DCSM , so if one
circuit becomes open, both seats can still be operated. However, if a fault occurs setting a DTC specific to
either climate controlled seat, only the affected seat will be disabled by the DCSM .
The DCSM receives all control commands over the Controller Area Network (CAN) communication circuits
from the HVAC module which contains the climate controlled seat switches. The climate controlled seat
system can only operate if both the HVAC and DCSM are communicating correctly on the CAN circuits.

Medium Speed Controller Area Network (MS-CAN) fault
HVAC module
DCSM
PINPOINT TEST Q: A SINGLE CLIMATE CONTROLLED SEAT IS INOPERATIVE - SWITCH INDICATORS MAY OR
MAY NOT ILLUMINATE

Q1 CHECK OPERATION OF BOTH CLIMATE
CONTROLLED SEATS AND VERIFY THE SYMPTOM
Yes
Check the operation of both climate controlled seats and verify GO to Q2 .
the symptom.
Is only a single climate controlled seat inoperative? No
If both seats are inoperative, GO
to Symptom Chart .
Q2 CHECK FOR DCSM AND HVAC MODULE DTCs
Yes
Enter the following diagnostic mode on the scan tool: Self Test For DCSM DTCs, GO to the
- DCSM . Dual Climate Controlled Seat
Enter the following diagnostic mode on the scan tool: Self Test Module (DCSM) DTC Chart.
- HVAC module.
Were any DTCs retrieved? For HVAC module DTCs,
REFER to Section 412-00 to
diagnose the HVAC module
fault.
No
GO to Q3 .
Q3 CHECK OPERATION OF THE DCSM USING PIDs
Yes
NOTE: The purpose of this step is to verify the pan title="Dual GO to Q4 .
Climate Controlled Seat Module" class="popup"
onmouseover="this.className='popupnounderline';" No
onmouseout="this.className='popup';">DCSM is able to INSTALL a new DCSM .
receive and process inbound command messages from the REFER to Dual Climate
communication bus and demonstrate if the DCSM is Controlled Seat Module
operational. This indicates the HVAC module may not be (DCSM) in this section. CLEAR
sending the commands correctly. the DTCs. REPEAT the
self-test.
DataLogger - DCSM .
Driver Seat
PINPOINT TEST Q: A SINGLE CLIMATE CONTROLLED SEAT IS INOPERATIVE - SWITCH INDICATORS

442
Seat cushion thermal electric device temperature

(CSHTEMP)
Seat back thermal electric device temperature
(BK_TEMP)
Climate-controlled seat heat command ( TED
_HEAT_D)
Front Passenger Seat
Passenger Cushion Thermo-Electric Device (TED)
Temperature (PCSHTMP)
Passenger Back TED Temperature (PBKTMP)
Passenger TED Heat Mode ( TED _HEAT_P)
NOTE: The DCSM ctive commands TED _HEAT_D (driver
seat) and TED _HEAT_P (passenger seat) are limited to 15
seconds in the ON state, then turn OFF.
Operate the affected climate controlled seat using the active
command while monitoring the appropriate PIDs.
When the command is in process the TED temperature
PIDs should momentarily increase. If no temperature
increase is noted, remove the cushion blower filter and
repeat the active command while physically
monitoring the cushion blower for fan movement.
Do the PID states or cushion blower movement indicate
climate controlled seat operation when using the active
command?
Q4 USE THE CLIMATE CONTROLLED SEAT SWITCH AND
MONITOR THE DCSM PID FOR A RESPONSE
Yes
Enter the following diagnostic mode on the scan tool: If the fault is intermittent,
DataLogger - DCSM . CHECK for causes of the
Driver State Seat Mode (DCCSMOD) (driver seat) intermittent fault. INSPECT the
Passenger State Seat Mode (PCCSMOD) (passenger connectors, terminals and
seat) wiring. AEMPT to recreate the
Start the engine. fault by flexing the wire harness
NOTE: Operation of the climate controlled seats repeatedly and operating the system.
ON and OFF or repeatedly switching between heat and cool CHECK the electrical
modes may cause DCSM DTCs to set, disabling one or both connectors for corrosion, poor
seat system and may require DTCs to be cleared before seat pin contact or pushed-out pins.
operation may continue. It is recommended to allow time REPAIR any intermittent
between modes for seat temperatures to return toward ambient concerns found and TIGHTEN
temperatures before continuing. any loose DCSM connector
Attempt to operate the affected climate controlled seat in all pins. CLEAR the DTCs.
modes using the switch buttons while monitoring the DCSM REPEAT the self-test.
PID DCCSMOD (driver seat) or PCCSMOD (passenger seat).
Do all the PID states match the climate controlled seat No
settings selected? INSTALL a new HVAC
module. REFER to Section
Pinpoint Test R: The Heated Seats are Inoperative - Rear
PINPOINT TEST Q: A SINGLE CLIMATE CONTROLLED SEAT IS INOPERATIVE - SWITCH INDICATORS

443
Normal Operation
The heated seat module receives battery voltage on circuit SBP18 (YE/RD) and ignition voltage on circuit
CBP35 (YE/GY), and is supplied ground on circuit GD143 (BK/VT). With the ignition switch in RUN or
START, when the left rear heated seat control switch is pressed, a ground is supplied on circuit CHS46
(YE/GN) to command the system on or off in high heat mode or circuit CHS47 (VT/GN) to command the
system on orff in low heat mode. When the right rear heated seat control switch is pressed with the ignition
switch in RUN or START, a ground is supplied on circuit CHS50 (BU/GY) to command the system on or off
in high heat mode or circuit CHS51 (YE/GY) to command the system on or off in low heat mode. When
commanded on, voltage is supplied to the heated seat switch from the heated seat module on either circuit
CHS48 (YE) (left rear) or CHS52 (BU) (right rear) (high heat mode) or circuit CHS49 (VT) (left rear) or
CHS53 (WH/BN) (right rear) (low heat mode) illuminating the switch indicator. The heated seat module also
supplies voltage to the cushion and backrest heater mats on circuit CHS39 (GN/BU) (left rear) or CHS43
(GY/BU) (right rear) and ground to the heater mats on circuit GD147 (BK/VT) (left rear) or GD148 (BK/YE)
(right rear). The cushion and backrest heater mats are connected in series and operate together. Temperature is
maintained by the heated seat module using a sensor contained within the cushion heater mat. The heated seat
module monitors the temperature sensors on circuit VHS42 (GN) (left rear) or VHS45 (GY/BN) (right rear)
for adjusting the current flow to the heater mats and uses a ground supplied on circuit RHS41 (GN/BN). The
heated seat module is designed to remain on, heating the seat and maintaining temperature until switched off
or the ignition voltage is switched OFF.
A new heated seat module must be configured after installation for correct operation. To configure, press the
low heat mode button on either rear heated seat switch. Module configuration will occur automatically after
the low heat mode button is pressed. Until the module is correctly configured, the heated seats will operate
incorrectly when selecting the high heat mode by following a sequence of high, low and off with each button
press. The system will operate correctly after the heated seat module receives a low heat request on either of
the low heat request circuits and rear heated seat module configuration is activated.

Fuse(s)
Heated seat module
PINPOINT TEST R: THE HEATED SEATS ARE INOPERATIVE - REAR

R1 CHECK FOR VOLTAGE TO THE REAR
HEATED SEAT MODULE
Yes
Disconnect: Heated Seat Module C3054B. GO to R2 .
Ignition ON.
Measure the voltage between: No
heated seat module C3054B-2, circuit VERIFY Smart Junction Box (SJB) fuses 18
CBP35 (YE/GY), harness side and (20A) and 35 (10A) are OK. If OK, REPAIR the
ground. circuit(s). If not OK, REFER to the Wiring
heated seat module C3054B-1, circuit Diagra manual to identify possible causes of the
SBP18 (YE/RD), harness side and circuit short. TEST the system for normal
ground. operation.

Are the voltages greater than 10 volts?

R2 CHECK THE HEATED SEAT MODULE
Yes
Ignition OFF. GO to R3 .
Measure the resistance between heated seat
module C3054B-5, circuit GD143 (BK/VT), No
harness side and ground. REPAIR the circuit(s). TEST the system for
normal operation.

R3 CHECK THE REAR HEATED SEAT
SWITCH INPUT GROUND CIRCUIT FOR AN
OPEN
Yes
Disconnect: Heated Seat Module C3054A. GO to R4 .
Measure the resistance between heated seat
module C3054A-2, circuit CHS46 (YE/GN), No
harness side and ground while pressing the REPAIR circuit GD143 (BK/VT). TEST the
driver heated seat switch to high. system for normal operation.
Is the resistance less than 30 ohms when

the heated seat switch is pressed and
greater than 10,000 ohms when the heated
seat switch is not pressed?
R4 CHECK THE TEMPERATURE SENSOR
RETURN CIRCUIT FOR AN OPEN
PINPOINT TEST R: THE HEATED SEATS ARE INOPERATIVE - REAR 445

Measure the resistance between heated seat Yes

module C3054A-12, circuit RHS41 (GN/BN), GO to R5 .
harness side and left rear heated seat
C3054A-3, circuit VHS42 (GN), harness side. No
REPAIR circuit RHS41 (GN/BN). TEST the
Is the resistance between 300 and 300,000

ohms?
R5 CHECK THE HEATER MATS GROUND
CIRCUIT FOR AN OPEN
Yes
Measure the resistance between heated seat INSTALL a new heated seat module. REFER to
module C3054B-4, circuit CHS39 (GN/BU), Heated Seat Module - Second Row in this section.
harness side and ground. TEST the system for normal operation.
No
REPAIR circuit GD150 (BK/WH). TEST the
Is the resistance between 3 and 5 ohms?
Pinpoint Test S: The Heated Seat is Inoperative - Left Rear
Normal Operation
The Battery Junction Box (BJB) supplies battery voltage to the heated seat module on circuit SBP18
(YE/RD), ignition voltage is supplied from the Smart Junction Box (SJB) on circuit CPB35 GY) and ground
on circuit GD143 (BK/VT). When the heated seat control switch is pressed, a ground signal is sent to the
heated seat module to command the system ON or OFF in HI heat mode or LOW heat mode. When
commanded ON, a ground signal is supplied from the heated seat switch to the heated seat module on either
circuit CHS46 (YE/GN) (HI heat mode) or circuit CHS47 (VT/GN) (LO heat mode) illuminating the switch
indicator. The heated seat module also supplies voltage to the cushion and backrest heater mats on circuit
CHS39 (GN/BU) and ground to the heater mats on circuit GD150 (BK/WH). The cushion and backrest heater
mats are connected in series and operate together. Temperature is maintained by the heated seat module using
a sensor contained within the cushion heater mat. The heated seat module supplies a reference voltage to the
temperature sensor on circuit VHS42 (GN) and monitors the temperature sensor for adjusting the current flow
to the heater mats. The heated seat module is designed to remain ON, heating the seat and maintaining
temperature until switched OFF.

Fuse
Heater mat
Heated seat switch
Heated seat module
PINPOINT TEST S: THE HEATED SEAT IS INOPERATIVE - LEFT REAR

S1 CHECK THE HEATED SEAT OPERATION
Yes
Ignition ON. If only the LOW setting operates,
Operate the left rear heated seat switch. GO to S15 .
Does the seat operate in either setting?
If only the HIGH setting operates,
GO to S16 .
No
GO to S2 .
S2 CHECK THE HEATED SEAT SWITCH INPUT
Yes
Disconnect: Heated Seat Module C3054A. GO to S4 .
Measure the resistance between heated seat module
C3054A-2, circuit CHS46 (YE/GN), harness side and No
ground while pressing the left rear heated seat switch to GO to S3 .
high.
Is the resistance less than 30 ohms when the heated seat

switch is pressed and greater than 10,000 ohms when the
heated seat switch is not pressed?
S3 CHECK THE HEATED SEAT SWITCH GROUND
CIRCUIT FOR AN OPEN
Yes
Disconnect: Left Rear Heated Seat Switch C3181. GO to S17 .
Measure the resistance between left rear heated seat switch
C3181-1, circuit GD143 (BK/VT), harness side and ground. No
PINPOINT TEST S: THE HEATED SEAT IS INOPERATIVE - LEFT REAR 447


S4 CHECK FOR VOLTAGE TO THE HEATED SEAT
MODULE
Yes
Disconnect: Heated Seat Module C3054B. GO to S5 .
Measure the voltage between heated seat module C3054B-1,
circuit SBP18 (YE/RD, harness side and ground. No

S5 CHECK THE HEATER MATS RESISTANCE AND
HEATER CIRCUITS FOR AN OPEN
Yes
Measure the resistance between heated seat module GO to S11 .
C3054B-4, circuit CHS39 (GN/BU), harness side and
ground. No
GO to S6 .

S6 CHECK THE HEATER MATS GROUND CIRCUIT FOR
AN OPEN
Yes
Disconnect: Left Rear Backrest Heater Mat C3360. GO to S7 .
Measure the resistance between left rear backrest heater mat
C3360-2, circuit GD150 (BK/WH), harness side and ground. No


S7 CHECK THE SWITCH INPUT CIRCUIT FOR AN OPEN
OR SHORT TO GROUND
Yes
Disconnect: Left Rear Seat Cushion C3361. GO to S8 .
heated seat module C3054B-4, circuit CHS39 No
(GN/BU), harness side and left rear seat cushion REPAIR the circuit. TEST the
heater mat C3361-1, circuit CHS39 (GN/BU), system for normal operation.
harness side.
heated seat module C3054B-4, circuit CHS39
(GN/BU), harness side and ground.
Is the resistance less than 5 ohms between C3054B-4 and

C3361-1, and greater than 10,000 ohms between
C3054B-4 and ground?
S8 CHECK CUSHION HEATER MAT FOR AN OPEN
Yes
Measure the resistance between left rear heated seat cushion GO to S9 .
C3361 pins 1 and pin 4, component side.
No
INSTALL a new rear seat cushion
heater mat. REFER to Seat
Cushion Heater Mat in this
normal operation.
Is the resistance between 0.7 and 1.5 ohms?

S9 CHECK THE CIRCUIT BETWEEN THE CUSHION AND
BACKREST HEATER MATS FOR AN OPEN OR A SHORT
TO GROUND

Measure the resistance between: Yes

left rear seat cushion heater mat C3361-4, circuit GO to S10 .
CHS40 (GY/VT), harness side and left rear seat
backrest heater mat C3360-1, circuit CHS40 No
(GY/VT), harness side. REPAIR the circuit. TEST the
left rear seat cushion heater mat C3361-4, circuit system for normal operation.
CHS40 (GY/VT), harness side and ground.
Is the resistance less than 5 ohms between C3361-4 and

C3361-1, and greater than 10,000 ohms between C3361-4
and ground?
S10 CHECK THE BACKREST HEATER MAT FOR AN
OPEN
Yes
Measure the resistance between left rear backrest heater mat GO to S11 .
C3360 pins 1 and 2, component side.
No
INSTALL a new rear seat backrest
Backrest Heater Mat in this
normal operation.

S11 CHECK THE TEMPERATURE SENSOR INPUT
Yes
Ignition ON. REPAIR the circuit. GO to S14 to
Measure the voltage between heated seat module C3054A-3, check the temperature sensor for
circuit VHS42 (GN), harness side and ground. damage. If temperature sensor is
OK, TEST the system for normal
operation.
No
GO to S12 .

S12 CHECK THE TEMPERATURE SENSOR INPUT

Ignition OFF. Yes

Measure the resistance between heated seat module GO to S13 .
C3054A-3, circuit VHS42 (GN), harness side and ground.
No
REPAIR circuit VHS42 (GN).
TEST the system for normal
operation.

S13 CHECK THE TEMPERATURE SENSOR CIRCUITS
Yes
Connect: Left Rear Seat Cushion C3361 (if previously INSTALL a new heated seat
disconnected). module. REFER to Heated Seat
Measure the resistance between: Module - Second Row in this
heated seat module C3054A-3, circuit VHS42 (GN), section. TEST the system for
harness side and C3054A-12, circuit RHS41 normal operation.
(GN/BN), harness side.
heated seat module C3054A-3, circuit VHS42 (GN), No
harness side and ground. GO to S14 .
Is the resistance greater than 300 and less than 300,000

ohms between C3054A-3 and C3054A-12 and greater
than 10,000 ohms between C3054A-12 and ground?
S14 CHECK THE TEMPERATURE SENSOR FOR AN OPEN
Yes
Disconnect: Left Rear Seat Cushion C3361. REPAIR circuit RHS41 (GN/BU)
Measure the resistance between left rear heated seat cushion or VHS42 (GN). TEST the system
C3361 pins 2 and 3, component side. for normal operation.
No
INSTALL a new rear seat cushion
Cushion Heater Mat in this
normal operation.
Is the resistance between 8,000 ohms and 15,000 ohms?

S15 CHECK THE HEATED SEAT SWITCH HIGH CIRCUIT

Disconnect: Heated Seat Switch C3181. Yes

Measure the resistance between: GO to S17 .
heated seat module C3054A-2, circuit CHS46
(YE/GN), harness side and left rear heated seat No
switch C3181-6, circuit CHS46 (YE/GN), harness REPAIR the circuit. TEST the
side. system for normal operation.
(YE/GN), harness side and ground.
Is the resistance less than 5 ohms between the heated seat

module and the heated seat switch and greater than
10,000 ohms between the heated seat module and
ground?
S16 CHECK THE HEATED SEAT SWITCH LOW CIRCUIT
Yes
Disconnect: Heated Seat Switch C3181. GO to S17 .
heated seat module C3054A-1, circuit CHS47 No
(VT/GN), harness side and left rear heated seat REPAIR the circuit. TEST the
switch C3181-2, circuit CHS47 (VT/GN), harness system for normal operation.
side.
(YE/GN), harness side and ground.
Is the resistance less than 5 ohms between the heated seat

module and the heated seat switch and greater than
10,000 ohms between the heated seat module and
ground?
S17 CHECK THE REAR HEATED SEAT SWITCH
Yes
Disconnect: Heated Seat Switch C3181. INSTALL a new heated seat
Measure the resistance between rear heated seat switch pins, module. REFER to Heated Seat
component side, while pressing the indicated switch buttons Module - Second Row in this
and compare the results to the table. section. TEST the system for
normal operation.
No

Heated Seat Switch Mode Pins Ohms INSTALL a new rear heated seat
High 6 and 1 Less than 30 switch. REFER to Heated Seat
Switch - Second Row in this
Low 2 and 1 Less than 75 section.
At rest 6 and 1 Greater than 10,000
At rest 2 and 1 Greater than 10,000
Is the heated seat switch OK?
Pinpoint Test T: The Heated Seat is Inoperative - Right Rear
Normal Operation
The Battery Junction Box (BJB) supplies battery voltage to the heated seat module on circuit SBP18
(YE/RD), ignition voltage is supplied from the Smart Junction Box (SJB) on circuit CPB35 (YE/GY) and
ground on circuit GD145 (BK/BU). When the heated seat control switch is pressed, a ground signal is sent to
the heated seat module to command the system ON or OFF heat mode or LOW heat mode. When commanded
ON, a ground signal is supplied from the heated seat switch to the heated seat module on either circuit CHS48
(YE) (HI heat mode) or CHS49 (VT) (LO heat mode) illuminating the switch indicator. The heated seat
module also supplies voltage to the cushion and backrest heater mats on circuit CHS39 (GN/BU) and ground
to the heater mats on circuit GD145 (BK/BU). The cushion and backrest heater mats are connected in series
and operate together. Temperature is maintained by the heated seat module using a sensor contained within
the cushion heater mat. The heated seat module supplies a reference voltage to the temperature sensor on
circuit VHS42 (GN) and monitors the temperature sensor for adjusting the current flow to the heater mats.
The heated seat module is designed to remain ON, heating the seat and maintaining temperature until
switched OFF.

Fuse
Heater mat
Heated seat switch
Heated seat module
PINPOINT TEST T: THE HEATED SEAT IS INOPERATIVE - RIGHT REAR

T1 CHECK THE HEATED SEAT OPERATION
Yes
Ignition ON. If only the low setting operates, GO to

Operate the right rear heated seat switch. T15.

Does the seat operate in either setting?
If only the high setting operates, GO to
T16 .
No
GO to T2 .
T2 CHECK THE HEATED SEAT SWITCH INPUT
Yes
Disconnect: Heated Seat Module C3054A. GO to T4 .
C3054A-8, circuit CHS50 (BU/GY), harness side and No
ground while pressing the heated seat switch to high. GO to T3 .
Is the resistance less than 30 ohms when the heated

seat switch is pressed and greater than 10,000
ohms when the heated seat switch is not pressed?
T3 CHECK THE HEATED SEAT SWITCH GROUND
CIRCUIT FOR AN OPEN
Yes
Disconnect: Right Rear Heated Seat Switch C3182. GO to T17 .
Measure the resistance between right rear heated seat
switch C3182-1, circuit GD143 (BK/VT), harness side No
and ground. REPAIR the circuit. TEST the system for
normal operation.

T4 CHECK FOR VOLTAGE TO THE HEATED SEAT
MODULE
Yes
Disconnect: Heated Seat Module C3054B. GO to T5 .
Measure the voltage between heated seat module
C3054B-3, circuit SBP18 (YE/RD), harness side and No
ground. REPAIR the circuit. TEST the system for
normal operation.
PINPOINT TEST T: THE HEATED SEAT IS INOPERATIVE - RIGHT REAR 454


T5 CHECK THE HEATER MATS RESISTANCE AND
HEATER MAT CIRCUITS FOR AN OPEN
Yes
Measure the resistance between heated seat module GO to T11 .
C3054B-6, circuit CHS43 (GY/BU), harness side and
ground. No
GO to T6 .

T6 CHECK THE HEATER MATS GROUND CIRCUIT
FOR AN OPEN
Yes
Disconnect: Right Rear Seat Backrest Heater Mat GO to T7 .
C3362.
Measure the resistance between passenger backrest No
heater mat C3362-2, circuit GD150 (BK/WH), harness REPAIR the circuit. TEST the system for
side and ground. normal operation.

T7 CHECK RIGHT REAR HEATER INPUT CIRCUIT
Yes
Disconnect: Rear Seat Cushion C3363. GO to T8 .
heated seat module C3054B-6, circuit CHS43 No
(GY/BU), harness side and right rear seat REPAIR the circuit. TEST the system for
cushion heater mat C3363B-1, circuit CHS43 normal operation.
(GY/BU), harness side.

heated seat module C3054B-6, circuit CHS43

(GY/BU), harness side and ground.
Is the resistance less than 5 ohms between

C3054B-6 and C3363-1, and greater than 10,000
ohms between C3054B-6 and ground?
T8 CHECK THE CUSHION HEATER MAT FOR AN
OPEN
Yes
Measure the resistance between rear heated seat GO to T9 .
cushion C3363 pins 1 and 4, component side.
No
INSTALL a new rear seat cushion heater
mat. REFER to Seat Cushion Heater Mat
in this section. TEST the system for
normal operation.

T9 CHECK THE CIRCUIT BETWEEN THE CUSHION
AND BACKREST HEATER MATS FOR AN OPEN OR
SHORT TO GROUND
Yes
Measure the resistance between: GO to T10 .
right rear seat cushion heater mat C3363-4,
circuit CHS44 (GN/VT), harness side and No
right rear seat backrest heater mat C3362-1, REPAIR the circuit. TEST the system for
circuit CHS44 (GN/VT), harness side. normal operation.
right rear seat cushion heater mat C3363-4,
circuit CHS44 (GN/VT), harness side and
ground.
Is the resistance less than 5 ohms between C3363-4

and C3362-1, and greater than 10,000 ohms
between C3363-4 and ground?

T10 CHECK THE BACKREST HEATER MAT FOR

AN OPEN
Yes
Measure the resistance between right rear seat GO to T11 .
backrest heater C3362 pins 1 and 2, component side.
No
INSTALL a new rear seat backrest heater
mat. REFER to Seat Backrest Heater Mat
normal operation.

T11 CHECK THE TEMPERATURE SENSOR
Yes
Ignition ON. REPAIR the circuit. GO to T14 to check
Measure the voltage between heated seat module the temperature sensor for damage. If
C3054A-9, circuit VHS45 (GY/BN), harness side and temperature sensor is OK, TEST the
ground. system for normal operation.
No
GO to T12 .

Yes
Ignition OFF. GO to T13 .
C3054A-9, circuit VHS45 (GY/BN), harness side and No
ground. REPAIR circuit VHS45 (GY/BN). TEST
Is the resistance greater than 10,000?

CIRCUITS FOR AN OPEN OR SHORT TO GROUND


heated seat module C3054A-9, circuit VHS45 INSTALL a new heated seat module.
(GY/BN), harness side and C3054A-12, REFER to Heated Seat Module - Second
circuit RHS41 (BK/BU), harness side. Row in this section. TEST the system for
heated seat module C3054A-9, circuit VHS45 normal operation.
No
GO to T14 .
Is the resistance greater than 300 and less than

300,000 ohms between C3054A-3 and C3054A-12
and greater than 10,000 ohms between C3054A-12
and ground?
T14 CHECK THE TEMPERATURE SENSOR FOR AN
OPEN
Yes
Disconnect: Right Rear Seat Cushion C3363. REPAIR circuit RHS41 (GN/BU) or
VHS45 (GY/BN). TEST the system for
i>Measure the resistance between rear heated seat normal operation.
cushion C3363 pin 2 and pin 3, component side.
No
INSTALL a new rear seat cushion heater
mat. REFER to Seat Cushion Heater Mat
normal operation.
Is the resistance between 8,000 ohms and 15,000

ohms?
T15 CHECK THE HEATED SEAT SWITCH HIGH
CIRCUIT FOR AN OPEN OR SHORT TO GROUND
Yes
Disconnect: Heated Seat Switch C3182. GO to T17 .
(BU/GY), harness side and right rear heated REPAIR the circuit. TEST the system for
seat switch C3182-6, circuit CHS50 normal operation.
(BU/GY), harness side.
(BU/GY), harness side and ground.

Is the resistance less than 5 ohms between the

heated seat module and the heated seat switch and
greater than 10,000 ohms between the heated seat
module and ground?
T16 CHECK THE HEATED SEAT SWITCH LOW
CIRCUIT FOR AN OPEN OR SHORT TO GROUND
Yes
Disconnect: Heated Seat Switch C3182. GO to T17 .
(YE/GY), harness side and right rear heated REPAIR the circuit. TEST the system for
seat switch C3182-2, circuit CHS51 (YE/GY), normal operation.
harness side.
(YE/GY), harness side and ground.
Is the resistance less than 5 ohms between the

heated seat module and the heated seat switch and
greater than 10,000 ohms between the heated seat
module and ground?
T17 CHECK THE HEATED SEAT SWITCH
Yes
Disconnect: Heated Seat Switch C3182. INSTALL a new heated seat module.
Measure the resistance between rear heated seat REFER to Heated Seat Module - Second
switch pins, component side, while pressing the Row in this section. TEST the system for
indicated switch buttons and compare the results to the normal operation.
table.
No
INSTALL a new rear heated seat switch.
REFER to Heated Seat Switch - Second
Row in this section.
Heated Seat Switch
Mode Pins Ohms
High 6 and 1 Less than 30
Low 2 and 1 Less than 75
At rest 6 and 1 Greater than
10,000
At rest 2 and 1

Greater than
10,000
Is the heated seat switch OK?
Pinpoint Test U: The Heated Seat Does Not Operate Correctly - Left Rear Seat Does Heat But the
Heated Seat Indicator Does Not Illuminate When Pressed
Normal Operation
Pressing the left rear heated seat switch once in either the high or low mode will activate the left rear heated
seat. Voltage is then supplied from the heated seat module to the appropriate switch indicator circuit CHS48
(YE) (high heat mode) or CHS49 (VT) (low heat mode) to illuminate the switch indicator. Pressing the switch
button again (in the same mode) will deactivate the seat and indicator.
low heat mode button on erear heated seat switch. Module configuration will occur automatically after the low
heat mode button is pressed. Until the module is correctly configured, the heated seats will operate incorrectly
when selecting the high heat mode by following a sequence of high, low and off with each button press. The
system will operate correctly after the heated seat module receives a low heat request on either of the low heat
request circuits and heated seat module configuration is activated.

Heated seat switch
Heated seat module
PINPOINT TEST U: THE HEATED SEAT DOES NOT OPERATE CORRECTLY - LEFT REAR SEAT DOES HEAT BUT
THE HEATED SEAT INDICATOR DOES NOT ILLUMINATE WHEN PRESSED

U1 CHECK THE HEATED SEAT INDICATOR
Yes
Disconnect: Left Rear Heated Seat Switch C3181. GO to U2 .
Disconnect: Heated Seat Module C3054A.
Measure the resistance between: No
heated seat module C3054A-4, circuit REPAIR the circuit(s). TEST the system
CHS49 (VT), harness side and ground. for normal operation.

heated seat module C3054A-5, circuit

CHS48 (YE), harness side and ground.

U2 CHECK THE HEATED SEAT INDICATOR
Yes
Measure the resistance between: GO to U3 .
CHS49 (VT), harness side and left rear No
heated seat switch C3181-3, circuit CHS49 REPAIR the circuit(s). TEST the system
(VT), harness side. for normal operation.
CHS48 (YE), harness side and left rear
heated seat switch C3181-4, circuit CHS48
(YE), harness side.

U3 CHECK THE HEATED SEAT HIGH INDICATOR
Yes
Connect: Left Rear Heated Seat Switch C3181. GO to U4 .
Disconnect: Heated Seat Module C3054B.
Ignition ON. No
Connect a fused jumper lead between heated seat INSTALL a new rear heated seat switch.
module C3054A-5, circuit CHS48 (YE), harness REFER to Heated Seat Switch - Second
side and C3054B-1, circuit SBP18 (YE/RD), Row in this section. TEST the system for
harness side. normal operation.
Does the high indicator illuminate?

U4 CHECK THE HEATED SEAT LOW INDICATOR
PINPOINT TEST U: THE HEATED SEAT DOES NOT OPERATE CORRECTLY - LEFT REAR SEAT
461 DOES
Connect a fused jumper lead between heated seat Yes

module C3054A-4, circuit CHS49 (VT), harness INSTALL a new heated seat module.
side and C3054B-1, circuit SBP18 (YE/RD), REFER to Heated Seat Module - Second
harness side. Row in this section. TEST the system for
normal operation.
No
INSTALL a new rear heated seat switch.
REFER to Heated Seat Switch - Second
Row in this section. TEST the system for
normal operation.
Does the low indicator illuminate?
Pinpoint Test V: The Heated Seat Does Not Operate Correctly - Right Rear Seat Does Heat But the
Heated Seat Indicator Does Not Illuminate When Pressed
Normal Operation
Pressing the right rear heated seat switch once in either the high or low mode will activate the left rear heated
seat. Voltage is then ed from the heated seat module to the appropriate switch indicator circuit CHS52 (BU)
(high heat mode) or CHS53 (WH/BN) (low heat mode) to illuminate the switch indicator. Pressing the switch
the low heat request circuits and heated seat module configuration is activated.

Heated seat switch
Heated seat module
PINPOINT TEST V: THE HEATED SEAT DOES NOT OPERATE CORRECTLY - RIGHT REAR SEAT DOES HEAT BUT
THE HEATED SEAT INDICATOR DOES NOT ILLUMINATE WHEN PRESSED

V1 CHECK THE HEATED SEAT INDICATOR

Disconnect: Right Rear Heated Seat Switch C3182. Yes

Disconnect: Heated Seat Module C3054A. GO to V2 .
heated seat module C3054A-10, circuit No
CHS53 (WH/BN), harness side and ground. REPAIR the circuit(s). TEST the system
heated seat module C3054A-11, circuit for normal operation.
CHS52 (BU), harness side and ground.

V2 CHECK THE HEATED SEAT INDICATOR
Yes
Measure the resistance between: GO to V3 .
CHS53 (WH/BN), harness side and right No
rear heated seat switch C3182-3, circuit REPAIR the circuit(s). TEST the system
CHS53 (WH/BN), harness side. for normal operation.
CHS52 (BU), harness side and right rear
heated seat switch C3182-4, circuit CHS52
(BU), harness side.

V3 CHECK THE HEATED SEAT HIGH INDICATOR
Yes
Connect: Right Rear Heated Seat Switch C3182. GO to V4 .
Ignition ON. No
Connect a fused jumper lead between heated seat INSTALL a new rear heated seat switch.
module C3054A-11, circuit CHS52 (BU), harness REFER to Heated Seat Switch - Second
side and C3054B-1, circuit SBP18 (YE/RD), harness Row in this section. TEST the system for
PINPOINT TEST V: THE HEATED SEAT DOES NOT OPERATE CORRECTLY - RIGHT REAR 463
SEAT DOE
Does the high indicator illuminate?

V4 CHECK THE HEATED SEAT LOW INDICATOR
Yes
INSTALL a new heated seat module. REFER to Heated Seat
Module - Second Row in this section. TEST the system for
normal operation.
No
INSTALL a new rear heated seat switch. REFER to Heated
Seat Switch - Second Row in this section. TEST the system
Pinpoint Test W: The Heated Seat Does Not Operate Correctly - Left Rear Heated Seat Indicator is
Always On
Normal Operation
Pressing the left rear heated seat switch once in either the high or low mode will activate the left rear heated
seat. Voltage is then supplied from the heated seat module to the appropriate switch indicator circuit CHS48
(YE) (high heat mode) or CHS49 (VT) (low heat mode) to illuminate the switch indicator. Pressing the switch
the low heat request circuits and heated seat module configuration is activated.

Heated seat module
PINPOINT TEST W: THE HEATED SEAT DOES NOT OPERATE CORRECTLY - LEFT REAR HEATED SEAT
INDICATOR IS ALWAYS ON
Result / Action to
Test Step
Take
W1 CHECK THE HEATED SEAT INDICATORS FOR A SHORT TO
VOLTAGE

Did the indicator turn off when the heated seat module was
disconnected?
PINPOINT TEST W: THE HEATED SEAT DOES NOT OPERATE CORRECTLY - LEFT REAR HEATED
465 SE

Memory Position Programming
Programming Memory Positions
1. Place the vehicle ignition to ON.
2. NOTE: To program an Integrated Keyhead Transmitter (IKT) (remote entry transmitter), refer to
Remote Keyless Entry Transmitter Programming and Remote Memory Activation in Section 501-14 .
To set memory position(s) move the memory driver seat, memory exterior mirrors (if equipped),
memory adjustable pedals (if equipped) and memory tilt steering column (if equipped) to the
preferred position using the appropriate switch(es).
3. NOTE: Activation of the driver seat control switch, adjustable pedal control switch, exterior mirror
control switch or power tilt steering column switch during memory programming will abort the
operation.
NOTE: If other tones or chimes are being produced, the memory save tone will not be heard because
it is one of the lowest priorities.
Press and hold a memory button (1 or 2) until a tone is heard (1.5 seconds). When the tone is heard,
the memory programming is complete.
4. Repeat the previous steps to program another memory position.
Recalling a Stored Memory Position
NOTE: A memory recall can be initiated only if the vehicle is in PARK or NEUTRAL gear and the ignition
is not in START. A memory recall in progress will not be affected by placing the ignition in START or by
moving the gearshift lever out of PARK or NEUTRAL.
NOTE: Input from the driver seat control switch, adjustable pedal control switch, exterior mirror control
switch or power tilt steering column switch during a memory recall will abort the operation.
1. The driver can recall the desired memory driver seat, memory exterior mirror (if equipped), memory
adjustable pedal (if equipped) and memory tilt steering column (if equipped) positions by depressing
either memory SET switch button 1 or 2. Depressing memory SET switch button 1 will initiate a
recall of the positions stored for Memory 1. Depressing memory SET switch button 2 will initiate a
recall of the positions stored for Memory 2.
Memory Position Programming 466

Memory Position Programming 467


Seat - Front
NOTE: Driver seat shown, passenger similar.
NOTE: For torque specifications and torque sequence, refer to the procedure steps.

1 62184 Front seat cushion panel shield
2 - Electrical connectors (part of 14A699)
3 618D49 Seat-to-floor front bolt cover
4 W708564 Seat-to-floor front bolts (2 required)
5 618D49 Seat-to-floor rear bolt covers (2 required)
6 W708564 Seat-to-floor rear outboard bolt
7 W710482 Seat-to-floor rear inboard bolt
Removal
WARNING: Never disassemble or tamper with safety belt buckle/retractor pretensioners, adaptive
load limiting retractors, safety belt inflators, or probe the electrical connectors. Failure to follow this
instruction may result in the accidental deployment of the safety betensioners, adaptive load limiting
retractors, or safety belt inflators, which increases the risk of serious personal injury or death.
WARNING: Never probe the electrical connectors on air bag, Safety Canopy or side air curtain
modules. Failure to follow this instruction may result in the accidental deployment of these modules,
which increases the risk of serious personal injury or death.
Seat - Front 468

1. Position the seat to access all seat-to-floor fasteners.
2. Depower the SRS . For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering in the General Procedures portion of Section 501-20B .
3. Remove the 2 seat-to-floor rear bolt covers.
4. Remove the 2 seat-to-floor rear bolts.
5. NOTICE: Do not pull from the inoard side of the front seat cushion panel shield to avoid
damaging it.
Remove the front seat cushion panel shield for electrical connector access.
Release the upper retaining clips working from the outboard side and then release the lower
retaining clips.
6. Remove the seat-to-floor front bolt cover.
7. Remove the 2 seat-to-floor front bolts.
8. Detach the pin-type retainer and vehicle wiring harness from the seat.
9. Disconnect the seat harness electrical connectors and remove the seat.
Slide the release button and disconnect the safety belt buckle pretensioner electrical
connector.
Slide the release button and disconnect the side air bag electrical connector.
Disconnect the seat harness electrical connector(s).
Release the locking tab and rotate the assurance lever fully.
Slightly tip the connector away and disconnect.
Installation
NOTE: The seat-to-floor bolts must be tightened in the sequence described in this procedure.
1. NOTE: Make sure the safety belt webbing is not twisted and the safety belts and buckles are
accessible to the occupants.
Position the seat in the vehicle and connect the electrical connectors.
Connect the seat harness electrical connector(s).

Make sure the assurance lever is fully released and partially insert the electrical
connector.
Seat - Front 469

Rotate the assurance lever while pushing the connectors together until the handle is
locked.
Connect the safety belt buckle pretensioner and side air bag electrical connectors.
Make sure the connectors are locked.
2. Install the wiring harness pin-type retainer.
3. Install the seat-to-floor bolts in the following sequence:

1. Install the seat-to-floor front inboard bolt.
2. Install the seat-to-floor front outboard bolt.
3. Install the seat-to-floor rear inboard bolt.
4. Install the seat-to-floor rear outboard bolt.
4. Install the front and 2 seat-to-floor rear bolt covers.
5. Install the front seat cushion panel shield.
6. Repower the SRS . For additional information, refer to Supplemental Restraint System (SRS)
Depowering and Repowering in the General Procedures portion of Section 501-20B .
Seat - Front 470


Seat - Exploded View, Front
Seat Backrest - Front, 40 Percent
NOTE: Driver power seat backrest shown, passenger and manual similar.

1 611A08 Head restraint
2 64416/64810 Backrest trim cover/foam pad
3 61019 Backrest frame assembly
4 610A16 Head restraint guide (2 required)
5 611D10 Side air bag module
6 N620480 Side air bag module nuts (if equipped)
7 14K155 Wiring harness, side air bag
8 14C712 Backrest Thermo-Electric Device (TED) (if equipped)
9 N803946 Scrivet (if equipped)
10 60108 Lumbar screws (4 required)
11 65500 Lumbar assembly
12 14A699 Wiring harness (if equipped)
13 60108 Backrest-to-seat track bolts (4 required)
Seat Cushion - Front, 40 Percent
NOTE: Driver memory seat shown, driver and passengereat similar.
Seat - Exploded View, Front 471


1 61711 Seat track assembly
2 W520114 Safety belt buckle pretensioner nut
3 61203 Safety belt buckle pretensioner
4 60108 Backrest-to-seat track bolts (4 required)
5 62900/632A22 Cushion trim cover/foam pad
6 63100 Seat cushion frame
7 18D508 Cushion Thermo-Electric Device (TED) (if equipped)
8 - TED screws (if equipped) (2 required)
9 - Cushion frame rear clip and strap (part of 63100) (2
sets required)
10 60108 Cushion frame-to-seat track bolts (4 required)
11 14A699 Wiring harness and bracket assembly
12 14C708 Driver Seat Module (DSM) (if equipped)
13 610C01 Manual lumbar actuator (if equipped)
14 - Manual lumbar cable (if equipped) (part of
15 60108 Manual lumbar actuator screw (if equipped) (2
required)
16 62163 Cushion side shield
17 - Cushion side shield screws (5 required)
18 14A707 Side shield cover
19 14711 Knob, power lumbar switch (if equipped)
20 14711 Knob, power recliner switch (if equipped)
21 14711 Knob, seat control switch
22 14A701 Seat control switch
23 14776 Memory SET switch (if equipped)
24 61737 Recliner handle (if equipped)
Seat Cushion - Front, 40 Percent 472

25 62622 Manual lumbar knob (if equipped)

26 60108 Wiring harness bracket screws (3 required)
27 19E880 Cushion TED filter (if equipped)
Seat Cushion - Front, 40 Percent 473


Seat Backrest - Front
WARNING: If the seat side air bag cover has been damaged or separated from its mounting, or if
the air bag material has been exposed, install a new seat side air bag module. Never try to repair the
seat side air bag module. Failure to follow these instructions may result in the seat side air bag
deploying incorrectly, which increases the risk of serious personal injury or death in a crash.
NOTE: If a side air bag deployment took place, a new seat back pad, trim cover and side air bag module and
nuts must be installed. The seat back frame should be installed new if necessary.
NOTE: For component identification and locations, refer to Seat - Exploded View, Front in this section.
NOTE: Note all backrest wire harness routing for correct installation.
All seats
1. Remove the seat. For additional information, refer to Seat - Front in this section.
2. If equipped, remove the manual lumbar knob.

Adjust the manual lumbar to the fully relaxed position.
Pull and remove the manual lumbar knob.
Seat with side shield insert
3. Release the retainers and remove the insert from the side shield.
For power seat, disconnect the electrical connector(s).
4. Remove the front side shield screw.
Seat Backrest - Front 474

5. Remove the 4 side shield screws.
Seat with side shield cover
7. Remove the side shield cover.

Pry and release the 2 tabs at the rear of the side shield cover.
If equipped, disconnect the electrical connector(s).
Slide the cover forward and remove.
All seats
9. Release the backrest lower J-strip and unzip the 2 side zippers.

10. If equipped, remove the manual lumbar actuator.
Make sure the lumbar is fully relaxed.
Remove the 2 screws and lumbar actuator.
Detach and route out the lumbar cable from the cushion.
Note cable routing for correct installation.
11. Remove the 2 side air bag module nuts.

12. Position the backrest foam aside and remove the side air bag module from the backrest frame. Then
slide the side air bag module out of the seat backrest cover deployment chute.
For installation, position the locator pin and mounting studs through the holes in the
deployment chute and backrest frame.
13. Disconnect the electrical connector and remove the side air bag module.
14. Detach the 3 pin-type retainers and side air bag wiring harness.
15. For power and climate controlled seat, disconnect the backrest wiring harness electrical connector and
route the wire harness from the cushion.
16. Release the cushion cover fastener from the rear inboard side.
17. Remove the 4 backrest frame-to-seat track bolts and backrest.

18. WARNING: Check the seat side air bag deployment chute for damage. The deployment
chute must not be repaired. If there is any damage to the deployment chute, a new seat back
trim cover and deployment chute must be installed as a unit. Failure to follow these instructions
may result in the seat side air bag module deploying incorrectly and increase the risk of serious
WARNING: Before installing the seat side air bag module/deployment chute assembly:
Inspect the side air bag module and mounting surfaces for any damage or foreign material.
Remove any foreign material from the mounting surfaces of the deployment chute, the seat
backrest frame mounting bracket and the air bag module cavity in the seat backrest foam pad.
Install new parts if damaged.
Failure to follow these instructions may result in the seat side air bag deploying incorrectly, which
increases the risk of serious personal injury or death in a crash.To install, reverse the removal
procedure.


Seat Backrest Cover - Front
WARNING: Front seat backrest trim covers installed on seats equipped with seat side air bags
cannot be repaired. A new trim cover must be installed. Cleaning is permissible. Failure to follow these
instructions may result in the seat side air bag module deploying incorrectly and increase the risk of
1. Remove the seat backrest. For additional information, refer to Seat Backrest - Front in this section.
2. Remove the head restraint.

Push in the RH guide button to release and remove the head restraint.
3. Partially invert the backrest cover and release the inner J-clip.
4. Remove the headrest guides.

Reach into the backrest and pinch the headrest guide ends together to release from the
backrest frame.
Pull the backrest trim cover away from the spring clips while pulling out the headrest guides.
The head restraint guides are not interchangeable. Note location for correct installation.
5. NOTICE: Use care when separating the backrest cover from the hook-and-loop strip, or the
hook-and-loop strip may be torn from the backrest foam pad.
Partially invert the backrest cover and remove the lower hog rings from the support wires.
6. Continue to invert the backrest cover and remove the upper hog rings.
Route the side air bag module deployment chute through the slot in the foam pad.
Note the side air bag module deployment chute routing for correct installation.
Seat Backrest Cover - Front 478

7. Remove the backrest cover.
WARNING: If the seat side air bag cover has been damaged or separated from its mounting,
or if the air bag material has been exposed, install a new seat side air bag module. Never try to
repair the seat side air bag module. Failure to follow these instructions may result in the seat
side air bag deploying incorrectly, which increases the risk of serious personal injury or death
in a crash.
Seat Backrest Cover - Front 479


Seat Cushion Cover - Front
All seats
instruction may result in the accidental deployment of the safety belt pretensioners, adaptive load
limiting retractors, or safety belt inflators, which increases the risk of serious personal injury or death.
removed and the ignition switch is ON.
NOTE: For additional component identification and locations, refer to Seat - Exploded View, Front in this
section.
NOTE: For correct installation, note wire harness routing.
2. If equipped, pull and remove the manual lumbar knob.
Side shield with insert
For power seat, disconnect the electrical connector(s).
Seat Cushion Cover - Front 480

Side shield with cover

Pry and release the 2 tabs at the rear of the side shield cover.
If equipped, disconnect the electrical connector(s).
Slide the cover forward and remove.
All seats
9. Remove the side shield.

Detach the rear pin-type retainer from the seat track and return it to the side shield before
installation.
For installation, hook the cushion cover flap at the rear outboard corner to the side shield.

10. If equipped, disconnect the Thermo-Electric Device (TED) electrical connector.
11. Remove the pin-type retainer attaching the cushion cover to the outboard side seat track.
12. If equipped, release and open the cushion cover sleeve around the wiring harness.
13. Remove the cushion frame from the seat track.

Remove the 4 cushion frame-to-seat track bolts.
Release the 2 cushion frame rear clips and straps from the seat track and remove the cushion
frame.
14. If equipped, remove the 2 screws and position aside the TED .
15. NOTICE: Use care when separating the cushion cover from the hook-and-loop strips or the
hook-and-loop strips may be torn from the cushion foam pad.
Release all cushion cover fasteners and invert to the hog rings.
16. Remove all hog rings and cushion cover.

If equipped, make sure the climate controlled seat manifold is correctly fitted to the cushion
foam before installing the cushion cover.
18. Install the seat. For additional information, refer to Seat - Front in this section.


Seat Track - Manual
2. Remove the inboard and outboard seat track rails.

Remove the 6 seat track rail-to-seat track nuts from the inboard and outboard seat track rails.
Remove the inboard and outboard seat track rails.
Release and separate the seat track adjust handle from the seat track rails.
Disconnect the spring.
Slightly bend the tab and detach the seat adjust handle from the inboard seat track
rail.
Note the spring position for correct installation.
Seat Track - Manual 483


Seat Track - Power
NOTE: If a new Driver Seat Module (DSM) has been installed, all seat and power tilt column (if equipped)
soft stops must be reset. If a new seat track, recline motor or power tilt column has been installed, only reset
the soft stops for that component being installed new. To reset the soft stops, refer to Principles of Operation
in this section.
All seats
1. Remove the affected seat. For additional information, refer to Seat - Front in this section.
3. Remove the safety belt buckle and pretensioner.

Remove the tie strap.
Disconnect the 2 electrical connectors.
Remove theafety belt buckle and pretensioner.
4. Release the cushion cover front and rear J-clips and rear hook-and-loop strip.
Climate controlled seats
5. NOTE: Use care when removing the Thermo-Electric Device (TED). The U-nuts can slip into the
cushion frame.
Remove the cushion TED .
Disconnect the electrical connector and detach the wire harness.

Remove the 2 screws and TED .
For correct installation, note wire harness routing.
Seat Track - Power 484

6. Release the 2 tabs and slide out the Dual Climate Controlled Seat Module (DCSM).
7. NOTE: When installing a new DCSM , it is necessary to carry out Programmable Module Installation
(PMI). For additional information, refer to Section 418-01 .
If passenger seat, remove the DCSM .
Cut and remove the wiring harness tie strap.

Release the 2 locking wedges.
Driver memory seat
8. Remove the DSM .

Release the 2 tabs and slide out the DSM .
All seats
9. Remove the cushion frame, foam pad and cushion cover assembly from the seat track.
Remove the 4 cushion frame-to-seat track bolts.
Release the 2 cushion frame rear clips and straps from the seat track and remove the cushion
frame.
10. Disconnect the 3 seat track motor electrical connectors.

For driver seat with memory, disconnect the additional 3 motor sensor electrical connectors.
11. Remove the wire harness.

Remove the 3 wire harness bracket screws.
Remove the tie strap and release the rear wire harness bracket clip from the seat track.
Separate the electrical connectors and wire harness from the seat track.
Remove the wire harness and bracket.

A new seat track will not be equipped with the seat position sensor shunt bracket. The seat
position sensor shunt bracket must be removed from the original seat track and transferred to
the new seat track.



Lumbar Assembly
All seats
3. Raise the backrest cover rear flap and release the foam pad flap from the backrest frame hooks.
4. Position aside the backrest cover and foam pad to gain access to the lumbar assembly bolts.
5. Remove the 4 screws and lumbar assembly.

If equipped, disconnect the electrical connector from the lumbar assembly.
If equipped, route out the manual lumbar cable.
Manual lumbar actuator removal
6. Remove the 2 screws and manual lumbar actuator.

Note manual lumbar cable routing for correct installation.
All seats
Lumbar Assembly 487


Seat Backrest Thermo-Electric Device
1. With the backrest fully forward, release the seat backrest cover lower rear J-clip and unzip the 2 side
zippers.
2. Remove the climate controlled seat Thermo-Electric Device (TED).

Disconnect the TED electrical connector.
Remove the scrivet.
Detach the 2 retainer clips from the backrest frame support wires.
Seat Backrest Thermo-Electric Device 488


Seat Cushion Thermo-Electric Device
2. NOTE: Use care when removing the Thermo-Electric Device (TED). The U-nuts can slip into the
cushion frame.
Remove the seat cushion TED .
Disconnect the electrical connector and detach the wire harness.

Remove the 2 screws and TED .
Seat Cushion Thermo-Electric Device 489


Dual Climate Controlled Seat Module (DCSM)
1. When installing a new Dual Climate Controlled Seat Module (DCSM), carry out the appropriate steps
in the Programmable Module Installation (PMI) procedure. For additional information, refer to
Section 418-01 .
2. NOTICE: Do not pull from the inboard side of the front seat cushion panel shield to avoid
damaging it.
Position the front passenger seat fully upward and remove the front seat cushion panel shield.
retaining clips.
3. Release the 2 tabs and slide out the DCSM .
4. Remove the DCSM .

Cut and remove the wiring harness tie strap.
Dual Climate Controlled Seat Module (DCSM) 490

6. If a new DCSM has been installed, carry out the appropriate steps in the Programmable Module
Installation (PMI) procedure. For additional information, refer to Section 418-01 .
Dual Climate Controlled Seat Module (DCSM) 491


Driver Seat Module (DSM)
NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges,
damage may result.
NOTE: Prior to the removal of the module, it is necessary to upload the module configuration information to
a scan tool. This information must be downloaded into the new Driver Seat Module (DSM) after installation.
For additional information, refer to Section 418-01 .
1. NOTE: This step is only necessary if the DSM is being replaced.
Upload the module configuration information from the DSM into the scan tool. For additional
information, refer to Section 418-01 .
2. NOTE: The module is accessed with the seat fully in the UP position.
Position the DSM forward to remove it from the bracket.
3. Disconnect the electrical connectors and remove the DSM .
4. NOTE: Once the DSM is installed (if it was replaced), it is necessary to download the module
configuration information from the scan tool into the new DSM . For additional information, refer to
Section 418-01 .
Driver Seat Module (DSM) 492


Seat Control Switch - Front
All seats
1. NOTICE: Do not pull from the inbde of the front seat cushion panel shield to avoid damaging it.
Remove the front seat cushion panel shield.
retaining clips.
Side shield with insert
Disconnect the electrical connector(s).
Side shield with cover
Seat Control Switch - Front 493

Disconnect the electrical connector(s).
All seats
5. Pull and remove the seat control switch button(s).

If equipped, remove the power recliner switch button.
6. Release the clips and remove the seat control switch.
Seat Control Switch - Front 494


Memory Set Switch
All seats
1. NOTICE: Do not pull from the inboard side of the front seat cushion panel shield to avoid
damaging it.
Remove the front seat cushion panel shield.
retaining clips.
Driver seat side shield with insert
Driver seat side shield with cover
Memory Set Switch 495

All seats
5. Release the clips and remove the memory SET switch.
6. To install, reverse the removal procede.
Memory Set Switch 496


Seat - Second Row, 20 Percent

1 666C00 Right side seat-to-floor bolt covers (2 required)
2 W708367 Right side seat-to-floor bolts (2 required)
3 666C00 Left side seat-to-floor bolt cover
4 W708367 Left side seat-to-floor bolt
5 666C00 Seat-to-floor front bolt covers (2 required)
7 666C00 Seat-to-floor rear bolt covers (2 required)
8 W505284 Seat-to-floor rear bolts (LH/RH)
Removal
NOTICE: When removing the seat-to-floor bolt covers, use a flat-blade screwdriver to pry beneath the
attaching metal clips or damage to the covers may result.
1. Fold the LH and RH seats to the E-Z entry position.
2. Remove the 2 right side seat-to-floor bolt covers.
4. Remove the left side seat-to-floor bolt cover.
5. Remove the left side seat-to-floor bolt.
Seat - Second Row, 20 Percent 497

6. Position the LH and RH seats upright.
7. Remove the 2 seat-to-floor front bolt covers.
8. Remove the 2 seat-to-floor rear bolt covers.
9. Remove the 2 seat-to-floor front bolts.
11. Remove the LH seat-to-floor rear bolt and then the RH seat-to-floor rear bolt.
12. Remove the seat.
Installation
Position the seat in the vehicle and align the locator pins to the holes in the floor.
3. Install the seat-to-floor bolts in the following sequence:

1. Install the RH seat-to-floor rear bolt.
2. Install the LH seat-to-floor rear bolt.
3. Install the 2 seat-to-floor front bolts.
4. Install the 3 right and left side seat-to-floor bolts (note, shoulder bolts do not tighten to seat
brackets).
4. Install the 2 seat-to-floor rear bolt covers.
5. Install the 2 seat-to-floor front bolt covers.
6. Install the left and 2 right side seat-to-floor bolt covers.



Seat - Second Row, 40 Percent
NOTE: RH shown, LH similar.

1 638B30A Seat-to-floor bolt front cover
3 638B30B Seat-to-floor bolt rear cover
4 W708175 Seat-to-floor rear bolts (2 required)
5 - Locator pins (part of 63161 frame assembly)
6 - Electrical connector (part of 14B510) (if equipped)
Removal
All seats
1. Place the seat in the E-Z entry position.
2. Remove the cover and 2 seat-to-floor rear bolts.

Remove any remaining retainers from the seat and reinstall to the cover before installation.
3. If equipped, disconnect the electrical connector and separate the wire harness from the seat.
4. NOTE: Do not place the seat in the kneeled position (cargo mode).
Latch the seat to the floor and lower the backrest.
5. NOTICE: The seat base must be in the locked position, using the shipping pin, prior to seat
removal, otherage to the seat linkage components may occur.
NOTE: Shown with the cushion removed for clarity.
Lock the shipping pin.
Using an appropriate tool, slide the shipping pin outward to engage and lock the seat base.
Align the seat base and shipping pin, as needed.

6. Remove the cover and 2 seat-to-floor front bolts.

Remove any remaining retainers from the seat and reinstall to the cover before installation.
7. Pull the recliner handle and release the latch feet.
Seat with inoperative latch, stuck to floor
8. Using an appropriate tool, manually release the latches from the striker plate.
Push inward on the outboard latch release lever.
All seats
9. Lift to disengage the 2 locator pins and remove the seat.
Installation
1. Position the seat in the vehicle.

Align the 2 locator pins to the floor holes.
Press downward and lock the latch feet to the floor.
2. Install the 2 seat-to-floor front bolts.

3. Install the seat-to-floor bolt front cover.
4. Using an appropriate tool, push the shipping pin fully inward to unlock the seat from the E-Z entry
position.
5. Release the seat to the E-Z entry position.
6. Install the 2 seat-to-floor rear bolts.


7. If equipped, connect the electrical connector and separate the wire harness from the seat.
8. Install the seat-to-floor rear bolt cover.
9. Check the seat for correct operation.

With the seat in the upright or the load floor position, both latch feet must lock to the strikers.
When releasing the seat to the E-Z entry position, the latches must release freely and not bind
to the strikers.
Make sure the safety belts and buckles are accessible to the occupants after installation.


Seat - Exploded View, Second Row
Seat Backrest - 20 Percent
Part
1 666C04 Safety belt guide cover
2 611D52 Foam, safety belt retractor
cover
3 613C46 Safety belt retractor cover
4 - Safety belt retractor guide (part
of 611B64)
5 611B64 Safety belt retractor
7 W504042 Safety belt retractor cover
screws (2 required)
8 W505274 Safety belt retractor bolt
9 - Backrest support panel screws
(part of 613A38) (8 required)
10 W701259 Pin-type retainers (2 required)
11 63518 Attaching straps (2 required)
12 613A38 Backrest support panel
13 - Screw, release handle (2
required)
14 62418 Release handle
15 624A08 Release handle bezel 16 613A38
Seat - Exploded View, Second Row 503

Backrest
frame
17 W506542 Backrest-to-cushion bolts (2
required)
18 613F18 Pivot bolt
19 W504042 Screw, pivot bolt cover
20 62178 Pivot bolt cover
Seat Cushion - 20 Percent

1 63804 Cushion trim cover
2 63840 Cushion foam pad
3 613F18 Swivel bolts
4 613A38 Backrest frame
6 613F18 Seat riser-to-cushion frame bolts (2 required)
7 W504042 Screw, LH pivot bolt cover
8 62178 Pivot bolt cover
9 613F18 Pivot bolt
10 W506542 Backrest-to-cushion bolts (2 required)
11 63160 Cushion frame
12 - Safety belt anchor bolt (part of 611B64)
13 60044 Safety belt buckletd>
14 N620483 Safety belt buckle nut
15 W704655 LH side shield screws (2 required)
Seat Backrest - 20 Percent 504

16 - Recliner cable
17 - Lower panel
18 - Pin-type retainers (3 required)
19 613A97 LH side shield
20 W704655 RH side shield screws (2 required)
21 63386 RH side shield
NOTE: LH seat shown, RH similar.

1 611A08 Head restraint
2 610A16 Head restraint guide (2 required)
3 66800 Backrest trim cover
4 14D696 Backrest heater mat (if equipped)
5 66801 Backrest foam pad
6 - Backrest frame (part of 600B02 frame assembly)
7 62418 Kneeling release handle
Seat Cushion - 40 Percent Seat
NOTE: LH seat shown, RH seat similar.
Seat Cushion - 20 Percent 505


1 63805 Cushion trim cover
2 14D698 Cushion heater mat (if equipped)
3 63841 Cushion foam pad
4 666L76 Outer recliner shield, inboard
5 61349 Inner recliner shield, inboard
6 60108 Screw, inboard recliner shield (2 required)
7 60108 Screws, outboard recliner shield (2 required)
8 67460 Inner recliner shield, outboard
9 601L60 Load floor release cable
10 - Bolt, safety belt buckle (part of 613D99)
11 613D99 Safety belt buckle
12 605W00 Release strap
13 600A47 Front upper pedestal cover
14 617D35 Recliner handle
15 60108 Screw, recliner handle
16 63388 Lower pedestal cover
17 60108 Screws, latch foot cover (5 required)
18 63388 Latch foot inner cov (2 required) (outboard side
shown)
19 63388 Latch foot outer cover (2 required) (outboard side
shown)
20 67460 Outer recliner shield, outboard
Seat Cushion - 40 Percent Seat 506

21 617D68 Recliner handle screw cover

22 63388 Lower pedestal screw cover
23 600A47 Rear upper pedestal cover
24 - Screws, lower pedestal cover (6 required) (part of
00A25)
Seat Cushion - 40 Percent Seat 507


Seat Armrest - Second Row

1 67112 LH/ 67113 RH Seat armrest
2 65476 Armrest bolt
3 - Release button (part of 67112 LH/ 67113 RH)
4 - Release clip (part of 67112 LH/ 67113 RH)
1. Insert a suitable tool below the inboard side of the armrest and push the release button inward at the
hinge point. The clip will release and the armrest will slide off the pin.

To install the armrest, push the release button and slide the armrest on the pin.
If the armrest bolt is loose, before installing the armrest, tighten to 45 Nm (33 lb-ft).
Seat Armrest - Second Row 508

Seat Armrest - Second Row 509


Seat Backrest - Second Row, 20 Percent
NOTE: For parts identification and locations, refer to Seat - Exploded View, Second Row in this section.
1. Remove the seat. For additional information, refer to Seat - Second Row, 20 Percent in this section.
2. Remove the screw and pivot bolt cover.

Route the attaching strap through the pivot bolt cover.
3. Release the 2 lower backrest cover J-clips.
4. Remove the pin-type retainer and detach the LH side attaching strap.
5. Remove the 2 screws and RH side shield.

Raise the backrest upright to access and remove the center screw.
Release the 2 pin-type retainers.
6. Remove the pin-type retainer and detach the RH attaching strap.

Note attaching strap routing for correct installation.
7. Remove the safety belt anchor bolt.

8. Remove the 2 pin-type retainers and lower panel.
9.
10. Release the 2 J-clips and remove the attaching straps.
11. Detach the latch release cable from the seat base.
Release the cable clamp.
Detach the cable end.
12. NOTICE: Use care when separating the cushion cover from the hook-and-loop strip, or the
hook-and-loop strip may be torn from the cushion foam pad.
Seat Backrest - Second Row, 20 Percent 510

Partially invert the backrest cover to access the backrest fasteners.
13. Position aside the foam pad and remove the 2 swivel bolts.
14. Remove the pivot bolt.

15. Remove the 2 backrest-to-cushion bolts.

16. Remove the seat backrest.

Route out the latch release cable.
Note the cable routing for correct installation.


Seat Backrest Cover - Second Row, 20 Percent

Route the attaching strap through the pivot bolt cover.
2. Release the 2 lower backrest cover J-clips.
3. Remove the pin-type retainer and detach the LH side attaching strap.
4. Remove the 2 screws and RH side shield.

Raise the backrest upright to access and remove the center screw.
5. Remove the pin-type retainer and detach the RH attaching strap.

Note attaching strap routing for correct installation.

8. Release the 3 lower J-clips and route the RH flap through the child safety seat anchorage.
9. Detach the 2 J-clips and remove the attaching straps.

10. Remove the safety belt guide cover.
Insert an appropriate tool into the holes and release the 3 locking tabs.
Detach the safety belt guide cover.
Route the safety belt webbing through the slot.
11. Remove the latch release handle bezel.
Release the upper tab and separate the bezel from the latch release handle.
12. NOTICE: Use care when separating the backrest cover from the hook-and-loop strip, or
the hook-and-loop strip may be torn from the backrest foam pad.
Partially invert the backrest cover to the row of hog rings.

13. Remove all hog rings and backrest cover.
Route the safety belt webbing through the backrest cover opening.
Seat Backrest Cover - Second Row, 20 Percent 512



Seat Backrest Cover - Second Row, 40 Percent
1. If equipped, remove the armrest. For additional information, refer to Seat Armrest - Second Row in
this section.
2. NOTICE: Use care when releasing the spring clips. They can fall inside the backrest frame.
Remove the head restraint.
Pull the backrest cover material away from the head restraint guide to access the spring clips.
Release the 2 spring clips by pushing on the side shown.
Note the spring clip position for correct installation.
Raise and remove the head restraint.
3. Position the backrest downward.
4. Remove the kneeling release (cargo mode) handle.

Raise the handle to access the cable.
Detach the cable jacket from the kneeling release handle.
Release the retainers and position aside the kneeling release handle.
5. Release the lower backrest cover J-clip.
6. Position aside the ba cover rear flap and remove the 4 pin-type retainers.
7. If equipped, disconnect the backrest heater mat electrical connector.

Release the cushion cover rear J-clip.
Disconnect the electrical connector.
Detach the electrical connector and heater mat wiring.

8. Raise the backrest and route the J-clip between the backrest and cushion.
9. NOTICE: Use care when separating the seat backrest trim cover from the hook-and-loop strip,
or the hook-and-loop strip may be torn from the seat backrest foam pad.
Invert the backrest cover to the row of hog rings.
Separate the hook-and-loop strips.

If equipped, route the heater mat wiring through the backrest cover.
10. Remove the row of hog rings.
11. Continue inverting the backrest cover to the head restraint guides.
12. NOTICE: Use care when separating the head restraints and spring clips to avoid tearing or
damaging the backrest cover.
Pinch the head restraint guide ends to release and remove the 2 head restraint guides.


Seat Backrest Heater Mat
Removal
NOTICE: Do not reinstall any heater mat after removal. The adhesive will not adhere correctly to the
foam pad causing it to bunch up or shift out of place. A new heater mat must be installed. Failure to
follow this instruction can result in seat component damage and system failure.
1. Remove the seat backrest cover. For additional information, refer to Seat Backrest Cover - Second
2. Route the heater mat wiring harness from the seat.

Note harness routing for correct installation.
3. NOTICE: Do not use a razor knife or other sharp tool to separate the heater mat from the foam
pad. Damage to the foam pad may result. Install a new foam pad if torn or burned.
Carefully peel the backrest heater mat from the foam pad and discard.
Only a thin layer of foam should peel off with the adhesive.
4. If burned or torn, remove and discard the backrest foam pad.
Installation
1. If needed, install a new backrest foam pad.
2. NOTICE: Remove all paper strips from the adhesive before applying the heater mat to the foam
pad. Otherwise, damage to the seat can occur.
Install the heater mat to the foam pad.
Align the heater mat square to the seat backrest with the narrow area of the heater mat tucked
into the valley of the foam pad and the wiring toward the lower edge.
Firmly apply the heater mat to the foam pad making sure it is straight and free of any wrinkles
that may show through the backrest cover.
3. Route the heater mat wire harness as noted in removal.
4. Install the seat backrest cover. For additional information, refer to Seat Backrest Cover - Second Row,
40 Percent in this section.
&nbspP>
Seat Backrest Heater Mat 516

Seat Backrest Heater Mat 517


Seat Cushion Cover - Second Row, 20 Percent
1. Release the 2 backrest cover lower J-clips.

Route out the attaching strap.
4. Lower the backrest, release the cushion cover rear J-clip and route between the cushion and backrest.
5. Release the hook-and-loop strip and remaining cushion cover J-clips.
6. Remove the cushion foam pad and cushion cover together.
7. NOTICE: Use care when separating the seat cushion cover from the hook-and-loop strip, or the
hook-and-loop strip may be torn from the seat cushion foam.
Release the hook-and-loop strips and invert the cushion cover to the row of hog rings.
8. Remove all hog rings and the cushion cover.
Seat Cushion Cover - Second Row, 20 Percent 518


Seat Cushion Cover - Second Row, 40 Percent
1. With the seat in the E-Z entry position, release the rear J-clip and partially invert the cushion cover.
2. Release the trim cover J-clips from both sides of the cushion.
3. Release the outer and inner rear J-clips from the cushion.
4. If equipped, disconnect and detach the cushion heater mat electrical connector and heater mat wiring.
5. Latch the seat to the floor and raise the backrest.
6. Release the front J-clip from the cushion.
7. Release the 2 cushion trim cover retainers from the 2 child safety seat lower anchors and tethers for
children anchors.
Pull the cushion trim cover rearward and release the 2 clips.
8. NOTICE: Use care when separating the seat cushion trim cover from the hook-and-loop strip,
or the hook-and-loop strip may be torn from the seat cushion foam.
Separate the hook-and-loop strips and invert the cushion trim cover to the row of hog rings.
9. Remove the row of hog rings.
10. Remove the cushion trim cover.

Route the trim cover from between the cushion and backrest.


Seat Cushion Heater Mat
Removal
NOTICE: Do not reinstall any heater mat after removal. The adhesive will not adhere correctly to the
foam pad causing it to bunch up or shift out of place. A new heater mat must be installed. Failure to
follow this instruction can result in seat component damage and system failure.
1. Remove the seat cushion trim cover. For additional information, refer to Seat Cushion Cover - Second
2. Route the heater mat wiring harness from the seat.

Note harness routing for correct installation.
3. NOTICE: Do not use a razor knife or other sharp tool to separate the heater mat from the foam
pad. Damage to the foam pad may result. Install a new foam pad if torn or burned.
Carefully peel the cushion heater mat from the foam pad and discard.
Only a thin layer of foam should peel off with the adhesive.
4. If burned or torn, remove and discard the cushion foam pad.
Installation
1. If needed, install a new cushion foam pad.
2. NOTICE: Remove all paper strips from the adhesive before applying the heater mat to the foam
pad. Otherwise, damage to the seat can occur.
Install the heater mat to the foam pad.
Align the heater mat square to the seat cushion with the narrow area of the heater mat tucked
into the valley of the foam pad and the wiring toward the rear edge of the seat cushion frame.
Firmly apply the heater mat to the foam pad making sure it is straight and free of any wrinkles
that may show through the cushion cover.
3. Route the heater mat wire harness as noted in removal.
4. Install the seat cushion cover. For additional information, refer to Seat Cushion Cover - Second Row,
40 Percent in this section.
Seat Cushion Heater Mat 521

Seat Cushion Heater Mat 522


Heated Seat Module - Second Row
NOTE: Bottom of floor console shown.

1 - Screw
2 14C724 Heated seat module
3 - Electrical connectors (part of 14B079)
4 - Front floor console
1. Remove the front floor console. For additional information, refer to Section 501-12 .
2. Disconnect the 2 heated seat module electrical connectors at the bottom of the front floor console.
3. Remove the screw and unhook the heated seat module.
5. Carry out the auto-configuration sequence to program the heated seat module for use with a dual
momentary switch.
Start the vehicle and push the low button on either heated seat switch.
Operate tseats, monitor the indicators and verify the system is operating correctly in high and
low.
Heated Seat Module - Second Row 523

Heated Seat Module - Second Row 524


Heated Seat Switch - Second Row
ItemPart Number Description

1 04567 Rear cup holder
2 W705289 Rear cup holder retainers clip (4 required)
3 - Heated seat switch electrical connector (part of
14B079)
4 W705289 Front floor console rear panel retainers clip (6
required)
5 14D695 RH rear heated seat switch
6 14D695 LH rear heated seat switch
7 045E24 Front floor console rear panel
8 W710806 Front floor console rear panel screw (2 required)
1. Release the 4 retainer clips and remove the rear cup holder.
Remove any remaining retainers from the floor console and reinstall to the cup holder before
installation.
2. Remove the front floor console rear panel.

Remove the 2 screws.
Release the 6 retainer clips and separate the rear panel.
Disconnect all the electrical connectors and remove the rear panel.
Remove any remaining retainers frofloor console and reinstall to the rear cover before
installation.
3. Release and remove the heated seat switch(es).
Heated Seat Switch - Second Row 525

Heated Seat Switch - Second Row 526


Seat - Third Row
NOTE: 60 percent seat shown, 40 percent seat similar.

1 W708818 Load floor panel
2 W708175 Mid-floor panel support bolts
3 20162 Mid-floor panel support
4 W505284 Seat-to-floor bolt, rear inboard
5 W708175 Seat-to-floor bolts (5 required)
6 666C00 Seat-to-floor bolt front covers (2 required)
7 - Electrical connector (part of 13A409)
8 - Locator pin (part of 600M47)
9 60108K Gasket (2 required)
NOTICE: To prevent possible damage to the third row seat or the safety belts, make sure that the safety
belts are not fastened when moving the seat to the load floor position.
NOTICE: Make sure that no objects such as books, purses or briefcases are on the floor in front of the
third row seats or on the seat cushion before lowering the backrest(s). Failure to follow this instmay
cause incorrect operation of the seat.
NOTE: The third row seat backrests must be in the raised position for removal of the third row seats.
Seat - Third Row 527

1. Remove the load floor panel.
2. Remove the 2 bolts and mid-floor panel support.

3. For a power-fold seat with inoperative motor, do the following to raise the backrest:
Insert an appropriate tool in the torque shaft at the outboard side of the third row power seat
motor and rotate to raise the seat backrest.
If seized, remove the power-fold seat motor. For additional information, refer to Power-Fold
Seat Motor in this section.
4. If equipped, disconnect the power-fold seat motor electrical connector and detach the wire harness.
5. Remove the 6 seat-to-floor bolts.

6. NOTE: Do not scuff the safety belt buckles when removing the 60 percent seat.
Lift and remove the seat from the vehicle.
For 60 percent seat, raise the seat support bar over the safety belt buckles.
To install, align the 2 locator pins to the holes in the floor.
For installation, make sure the 2 gaskets are positioned to the locator pins.



Seat - Exploded View, Third Row
Seat Backrest - 40 percent

1 611A08 Head restraint assembly
2 610A16 Head restraint guide
3 - Backrest support panel (part of 613A38)
4 - Backrest support panel-to-backrest frame
screws (part of 613A38) (8 required)
5 666C02 Manual latch handle
6 W505274 Manual latch handle-to-backrest support
panel screws (2 required)
7 - Manual latch release cable
8 - Pin-type retainers
11 624C32 Outboard slide bracket cover
12 W708686 Outboard slide bracket cover-to-outboard
slide bracket screw
13 613F18 Outboard slide bracket-to-backrest frame
nut
14 613F18 Outboard slide bracket-to-cushion frame
nut
16 624C30 Outboard slide bracket
17 624C33 Inboard slide bracket cover
Seat - Exploded View, Third Row 530

18 W708686 Inboard slide bracket cover-to-inboard

slide bracket screw
19 613F18 Inboard slide bracket-to-backrest frame
nut
20 613F18 Inboard slide bracket-to-cushion frame
nut
21 613F18 Inboard slide bracket-to-inboard latch nut
22 624C30 Inboard slide bracket
23 W700883 Inboard latch-to-backrest frame bolt (2
required)
24 613F18 Outboard latch-to-cushion frame bolt
26 60044 Safety belt buckle
27 - Safety belt buckle bolt (part of 60044)
28 613D60 Outboard latch
29 613D61 Inboard manual latch
30 600M46 Inboard power latch
31 N620480 Nut, support bar
32 60108 Bolt, support bar
33 - Support bar
34 14547 Power-fold seat motor and bracket
35 - Bolt, bracket-to-pivot (part of 14547)
36 - Bolt, bracket-to-latch (part of 14547)
37 - ower-fold seat motor (part of 14547)
38 - Torque shaft, power-fold seat motor (part
of 14547)
Seat Backrest - 40 percent 531


1 63804/63840 Cushion trim cover/foam pad
3 W708686 Outboard slide bracket cover-to-outboard slide bracket
screw
4 613F18 Outboard slide bracket-to-cushion frame nut
7 W708686 Inboard slide bracket cover-to-inboard slide bracket
screw
8 613F18 Inboard slide bracket-to-cushion frame nut
11 613F18 Riser-to-cushion frame bolts (2 required)
12 613E52 Riser
13 666C00 Riser cover (2 required)
Part
1 611A08 Head restraint assembly
2 610A16 Head restraint guide (2
required)
3 - Backrest support panel

4 W505274 Backrest support

panel-to-backrest frame screw
(15 required)
5 666C02 Manual latch handle
6 W505274 Manual latch
handle-to-backrest support
panel screws (2 required)
7 - Backrest release cable
9 666C04 Safety belt guide cover
11 W505274 Safety belt retractor cover
screws (4 required)
13 W505274 Safety belt retractor bolt (part
of 611B64)
14 611A70 Cover, safety belt webbing
16 W708686 Inboard slide bracket
cover-to-inboard slide bracket
screw
17 613F18 Inboard slide ket-to-backrest
frame nut
18 613F18 Inboard slide
bracket-to-cushion frame nut
bracket-to-inboard latch nut
22 W708686 Outboard slide bracket
cover-to-outboard slide bracket
screw
24 613F18 Outboard slide
bracket-to-backrest frame nut
bracket-to-outboard latch nut
27 - Safety belt anchor bolt (part of
611B64)
29 613F18 Inboard latch-to-backrest frame
bolt (2 required)
31 - Child safety seat tether anchor
(part of 613A39)
Seat Backrest - 60 Percent 533

32 - Child safety seat tether anchor

bolt (part of 613A39)
33 - Support bracket
34 - Bolt, support bracket
35 N620480 Nut, support bracket
36 613F18 Outboard latch-to-cushion
frame bolt
37 613D61 Outboard latch
38 600M47 Inboard manual latch 39 600M46 Inboard
power
latch
40 14547 Power-fold seat motor and
bracket
41 - Bolt, bracket-to-pivot (part of
14547)
42 - Bushing, power-fold seat motor
(part of 14547)
43 - Bolt, bracket-to-latch (part of
14547)
44 - Torque shaft, power-fold seat
motor (part of 14547)

1 63805/63841 Cushion trim cover/foam pad
3 W708686

Inboard slide bracket

cover-to-inboard slide bracket
screw
7 W708686 Outboard slide bracket
cover-to-outboard slide
bracket screw
613F18 Riser-to-cushion frame bolts
11 613E53 Riser
12 666C00 Riser covers (2 required)


Seat Backrest - Third Row, 40 Percent
NOTE: For parts identification and locations, refer to Seat - Exploded View, Third Row in this section.
All seats
1. Remove the seat. For additional information, refer to Seat - Third Row in this section.
2. Remove the 2 screws and inboard and outboard slide bracket covers.
3. Release the backrest cover lower and inboard J-clips.
Manual fold seat
4. Remove the manual seat cable.

1. Release the cable clamp.
2. Detach the cable end.
All seats
5. Remove the outboard slide bracket-to-backrest frame and outboard slide bracket-to-outboard latch
nuts.
6. Reminboard slide bracket-to-backrest frame and inboard slide bracket-to-inboard latch nuts.
7. Separate the backrest from the seat and remove.
Seat Backrest - Third Row, 40 Percent 536



All seats
2. Remove the 2 screws and inboard and outboard slide bracket covers.
3. Release the backrest cover lower and inboard J-clips.
Manual fold seats
4. Remove the manual seat cable.

1. Release the cable clamp.
2. Detach the cable end.
All seats
5. Remove the outboard slide bracket-to-backrest frame and outboard slide bracket-to-outboard latch
nuts.
6. Re inboard slide bracket-to-backrest frame and inboard slide bracket-to-inboard latch nuts.
7. Separate the backrest from the seat and remove.



Seat Backrest Cover - Third Row
All seats
1. Remove the seat. Refer to Seat - Third Row in this section.
2. Remove the seat backrest. Refer to Seat Backrest - Third Row, 40 Percent or Seat Backrest - Third
3. NOTICE: Use care when releasing the spring clips. They can fall inside the backrest frame.
Remove the head restraint.
Pull the trim cover material away from theint guide to access the spring clips.
Release the 2 spring clips by pushing on the side shown.
Note the spring clip position for correct installation.
Raise and remove the head restraint.
4. Release all backrest cover J-clips.
5. Remove all staples.
LH seat
6. Release the hook-and-loop strip.

Seat Backrest Cover - Third Row 540

Manual fold seat
9. Remove the 2 screws and manual latch handle and cable assembly.
All seats
10. Reach up into backrest and squeeze the head restraint guide ends together to release and pull the 2
head restraint guides out.
The head restraint guides are not interchangeable. Note location for correct installation.
11. NOTICE: Use care when separating the backrest cover from the hook-and-loop strip, or the
hook-and-loop strip may be torn from the backrest foam pad.
Separate the hook-and-loop strips and invert the backrest cover to the row of hog rings.
12. Remove all hog rings.

For LH seat backrest, route the safety belt webbing through the backrest cover.
Seat Backrest Cover - Third Row 541


Seat Cushion Cover - Third Row
2. Raise the cushion, separate the cushion cover hook-and-loop strips and release the J-clips.
3. Remove the cushion cover and foam pad from the cushion frame.
Separate the hook-and-loop strips and invert the cushion cover to the row of hog rings.
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Seat Cushion Cover - Third Row 542

Seat Cushion Cover - Third Row 543


Power-Fold Seat Motor
1. Remove the load floor panel.
2. Remove the 2 bolts and mid-floor panel support.

3. Disconnect the power seat motor electrical connector and detach the wiring harness.
4. Remove the bracket-to-pivot bolt and bushing from the power-fold seat motor.
Note bushing shoulder position for correct installation.
5. Remove the bracket-to-latch bolt and power-fold seat motor.

Slide the power-fold seat motor and bracket away from the latch and torque shaft.
For installation, slightly rotate the torque shaft until seated into the power-fold seat
motor.
Power-Fold Seat Motor 544


Seat Control Switch - Third Row

1 13530 Tray, RH rear quarter trim panel
2 31012 RH rear quarter trim panel
3 - Electrical connectors (part of wire harness 13A409)
4 14C715 LH and RH third row seat control switches
1. Release and remove the tray from the RH rear quarter trim panel.
2. NOTE: The LH and RH switch wiring harness electrical connectors are not interchangeable.
Remove the affected seat control switch.
Release the 2 retaining tabs and detach the seat control switch from the RH rear quarter trim
panel.
Pull the seat control switch through the opening and disconnect the electrical connector.
Seat Control Switch - Third Row 545

Seat Control Switch - Third Row 546


DISASSEMBLY AND ASSEMBLY Procedure revision date: 08/12/2010
Seat Backrest - Front
Disassembly and Assembly
1. Remove the seat backrest cover. For additional information, refer to Seat Backrest Cover - Front in
this section.
2. Release the lower flap from the backrest frame hooks and remove the backrest foam pad.
3. Remove the 4 bolts and lumbar assembly.

If equipped, disconnect the electrical connector from the lumbar assembly.
If equipped, route out the manual lumbar cable.
4. For climate controlled seat, remove the backrest Thermo-Electric Device (TED).
Disconnect the TED electrical connector.
Remove the scrivet.
Detach the 2 retainer clips from the backrest frame support wires.
5. If equipped, disconnect the recliner motor electrical connector.
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For power and climate controlled seat, detach the wire harness retainers and remove the backrest wiring
harness.
Note the wire harness routing for correct installation.
7. To assemble, reverse the disassembly procedure.



Seat Cushion - Front
NOTE: If a new Driver Seat Module (DSM) has been installed, all seat and power tilt column (if equipped)
soft stops must be reset. If a new seat track, recline motor or power tilt column has been installed, only reset
the soft stops for that component being installed new. To set the soft stops, refer to Principles of Operation in
this section.
All seats
2. Remove the seat cushion cover. For additional information, refer to Seat Cushion Cover - Front in this
section.
3. Remove the cushion foam pad.
4. Remove the safety belt buckle and pretensioner.

Remove the tie strap.
the 2 electrical connectors.
Remove the nut and safety belt buckle and pretensioner.
5. For driver seat, disconnect the seat track position sensor electrical connector and detach the wiring
harness pin-type retainer.
Climate controlled seat
6. Remove the cushion TED .

Detach the wiring harness and remove the TED .
Note wire harness routing for correct installation.
7. Release the 2 tabs and slide out the Dual Climate Controlled Seat Module (DCSM).
Seat Cushion - Front 549

8. NOTE: When installing a new DCSM , it is necessary to carry out Programmable Module Installation
(PMI). For additional information, refer to Section 418-01 .
For passenger seat, remove the DCSM .
Cut and remove the wire harness tie strap.

Power seat
9. If equipped, remove the DSM .

Release the 2 tabs and slide out the DSM .
10. Disconnect the 3 seat track motor electrical connectors.

For driver seat with memory, disconnect the 3 additional motor sensor electrical connectors.
11. Remove the wire harness.

Remove the 3 wire harness bracket screws.
Remove the tie strap and release the rear wire harness bracket clip from the seat track.
Separate the electrical connectors and wire harness from the seat track.
Remove the wire harness and bracket.
All seats
12. For manual seat, remove the inboard and outboard seat track rails.
Remove the 6 seat track rail-to-seat track nuts from the inboard and outboard seat track rails.
Remove the inboard and outboard seat track rails.
Release and separate the seat track adjust handle from the seat track rails.
Disconnect the spring.
Slightly bend the tab and detach the seat adjust handle from the inboard seat track
rail.
Note the spring position for correct installation.



Seat Backrest - Second Row, 20 Percent
1. Remove the seat backrest. For additional information, refer to Seat Backrest - Second Row, 20
Percent in this section.

Insert an appropriate tool into the holes and release the 3 locking tabs.
Detach the safety belt guide cover.
Route the safety belt webbing through the slot.
3. Remove the latch release handle bezel.

Release the upper tab and separate the bezel from the latch release handle.
4. NOTICE: Use care when separating the backrest trim cover from the hook-and-loop strip, or
the hook-and-loop strip may be torn from the backrest foam pad.
Separate the hook-and-loop strips and invert the backrest trim cover to the row of hog rings.
5. Remove all hog rings.
6. Continue inverting and remove the backrest cover.

Route the safety belt webbing throuackrest cover opening.
7. Remove the 2 pin-type retainers and foam pad.
8. Remove the safety belt retractor foam cover.
9. Remove the 2 screws and safety belt retractor cover.
10. Remove the safety belt retractor bolt.

11. Release the 2 tabs and detach the safety belt retractor guide.
12. Remove the safety belt retractor.

Route out the safety belt webbing, guide, tongue and anchor through the backrest frame.
Note safety belt routing for correct installation.
13. Release the pin-type retainer and detach the release cable from the backrest frame.

14. Remove the 2 screws, latch release handle and route out the cable.
15. Remove the 2 pin-type retainers and 2 attaching straps.
16. Remove the 8 backrest support panel screws.
To assemble, reverse the disassembly procedure.


Seat Cushion - Second Row, 20 Percent
1. Remove the seat backrest. For additional information, refer to Seat Backrest - Second Row, 20
Percent in this section.
2. Remove the 2 screws and LH side shield.
3. Remove the nut and safety belt buckle.

To install, align the anti-rotation tab.
4. Release the cushion cover front J-clip.
5. Remove the 2 riser-to-cushion frame bolts and cushion frame.

6. Release the hook-and-loop strip and remaining cushion cover J-clips.
7. Remove the cushion frame from the foam pad and cushion cover.
8. NOTICE: Use care when separating the seat cushion cover from the hook-and-loop strip, or the
hook-and-loop strip may be torn from the seat cushion foam.
Release the hook-and-loop strips and invert the cushion cthe row of hog rings.
Seat Cushion - Second Row, 20 Percent 554

Seat Cushion - Second Row, 20 Percent 555


1. Remove the seat backrest cover. For additional information, refer to Seat Backrest Cover - Third Row
in this section.
2. Remove the bolt and the safety belt buckle.

For installation, align the anti-rotation tab.
3. Remove the nut, screw and support bracket.
4. Remove the 2 inboard latch-to-backrest frame bolts and the inboard latch.
5. Remove the outboard latch-to-cushion frame bolt and the outboard latch.
6. Remove the 6 screws and the backrest support panel.


1. Remove the seat backrest cover. For additional information, refer to Seat Backrest Cover - Third Row
in this section.

3. Remove the backrest foam pad.
4. Remove the nut, screw and support bracket.
5. Remove the outboard latch-to-cushion frame bolt and outboard latch.

6. Remove the 2 inboard latch-to-backrest frame bolts and inboard latch.

7. Remove the 4 screws and safety belt retractor cover.

9. Pinch to release the safety belt guide and remove the safety belt retractor.
Route the backrest frame.
10. Remove the 15 screws and backrest support panel.
11. Remove the bolt and child safety seat tether anchor.



Seat Cushion - Third Row, 40 Percent
1. Remove the seat backrest. For additional information, refer to Seat Backrest - Third Row, 40 Percent
in this section.
2. Remove the inboard and outboard slide bracket-to-cushion frame nuts and slide bracket from both
sides of the seat cushion.
3. Remove the 2 seat riser-to-cushion frame bolts and riser.

4. Release the cushion cover J-clips and remove the cushion frame.
&nbsnbsp;
Seat Cushion - Third Row, 40 Percent 559


Seat Cushion - Third Row, 60 Percent
1. Remove the seat backrest. For additional information, refer to Seat Backrest - Third Row, 60 Percent
in this section.
2. Remove the inboard and outboard slide bracket-to-cushion frame nuts and slide bracket from both
sides of the seat cushion.
3. Remove the 2 seat riser-to-cushion frame bolts and riser.

4. Release the cushion cover J-clips and remove the cushion frame.


SECTION 501-11: Glass, Frames and Mechanisms 2011 Expedition, Navigator Workshop Manual
Material
Item Specification Fill

Capacity
Dow Urethane Adhesive - -
BetasealTM Express
Dow Urethane One Step Glass - -
Primer
BetaprimeTM 5500 / 5500A /
5500SA
Foam Core Butyl WSB-M3G143-B1 -
E69Z-19562-A
Lacquer Touch-Up Paint (match ESR-M2P100-C -
color to exterior grid wire)
PM-19500-XXXX
Rear Window Defroster Repair - -
PM-11 (US); CPM-11 (Canada)
Sika Urethane Adhesive - -
Sika Tack ASAP
Sika Urethane Metal and Glass - -
Primer
Sika 206 G+P
Silicone Spray Lubricant ESR-M13P4-A -
XL-6
TA-26
Ultra-Clear Spray Glass Cleaner ESR-M14P5-A -
ZC-23
General Specifications
Item Specification
Polypropylene Film Fine Line Tape (commercially available) -
Door glass regulator frame bolts 11 Front door glass channel bolt 11 97
Front door window glass clamp bolts 11 97
Liftgate glass hinge-to-body fastener 12 106
Liftgate glass-to-hinge bolts 8 71

Rear door glass channel bolts 11 97

Rear door stationary glass screw 5 44
Rear door window glass clamp bolt 11 97
Rear quarter window glass nuts 2 18
Rear quarter window regulator motor bolts 9 80
Window regulator bolts 11 97
Window regulator motor bolts 7 62

Glass, Frames and Mechanisms
The glass, frames and mechanisms consist of the:
front door window glass.

front door window motor.
front door window regulator.
rear quarter window glass.
rear quarter window glass frame.
rear quarter motor and window regulator.
rear door window glass.
rear door window motor.
rear door window regulator.
liftgate glass.
windshield glass.
The glass, frames and mechanisms include:
standard plastic and laminate safety glass.

liftgate glass which houses the rear defrost grid and rear wiper arm.
windshield glass which is bonded to the opening flange with a urethane sealant.
on Expedition, standard power windows which include one-touch up/down (LF only) and lock out
feature.
on Navigator, standard power windows which include one-touch up/down (LF and RF only) and lock
out feature.
power vented rear quarter windows.
fixed rear quarter windows (Expedition only).
RH quarter window glass antenna.
The window regulator control switch:
is located on each door trim panel.

may be used to raise or lower all windows from the master control on the driver side, or the individual
side window from the individual door switch.
on Expedition, includes a one-touch up and one-touch down double detent feature (LF only).
on Navigator, includes a one-touch up and one-touch down double detent feature (LF and RF).
can manually lower the driver side window when the master control is depressed halfway (first
detent).
will completely lower the driver side window when the master control is fully depressed and then
released (second detent).
will completely raise the driver side window when the master control is pulled up and then released
(second detent).
on Navigator, will completely lower the passenger front window when the RF control switch is fully
depressed and then released (second detent).
on Navigator, will completely raise the passenger front window when the RF control switch is pulled
up and then released (second detent).
can lock out passenger front (Expedition only) and rear control switches.
The rear quarter glass regulator control switches:
are located in the overhead console.
Glass, Frames and Mechanisms 564

may be used to open and close the RH or LH rear quarter windows.
stop the rear quarter glass in any position when released.
The power window system will operate if the ignition switch is in the RUN or ACC position, or the delayed
accessory feature is active.
Passenger windows may be raised or lowered using the LF master control switches or the appropriate
passenger window switch. Passenger window switches receive power when the delayed accessory relay is
active and the LF remote lock-out switch is in the UNLOCK position. When in the LOCK-OUT position, the
passenger windows are deactivated (Expedition only). When in the lock-out position, the rear windows are
deactivated (Navigator only).
The accessory delay relay, located in the SJB , provides power for the operation of the power windows and
the roof opening panel (if equipped). For Expedition (LF window only) and Navigator (LF and RF windows),
the accessory delay relay provides a low current signal to allow window movement. The accessory delay relay
is active when the ignition switch is in the RUN or the ACC position, or when the ignition switch is changed
from RUN or ACC to the OFF/LOCK position and the LF and RF doors are closed.
The accessory delay relay will deactivate when:
the LF door is ajar and the ignition switch is in the OFF/LOCK or KEY-OUT position.
the RF door is ajar and the ignition switch is in the OFF/LOCK or KEY-OUT position.
10 minutes have elapsed since the ignition switch was changed from ACC or RUN to the OFF/LOCK
position.
Feature inputs:
LF door open warning switch (open circuit with door closed, grounded with door ajar)
RF door open warning switch (open circuit with door closed, grounded with door ajar)
Ignition switch RUN position (battery potential on both the RUN and RUN/ACC inputs)
Ignition switch ACC position (battery potential on the RUN/ACC input)
Ignition switch OFF/LOCK position (absence of battery potential on the RUN, RUN/ACC and
START inputs)
Feature outputs:
Accessory delay relay (grounded when activated, open circuit when deactivated)
The HVAC module controls the state of the rear window defrost relay. When the rear window defrost switch
(integral to the HVAC module) is pressed, the HVAC module will activate the rear window defrost relay.
When the rear window defrost relay is active, both the rear window defrost grid and heated mirror elements
will be energized.
The HVAC module will deactivate the rear window defrost relay when one of the following conditions is met:
The rear window defrost switch is pressed when the feature is active
Ignition switch state is changed from RUN to OFF/LOCK
The 10 minute timing function is completed
Feature inputs:
Ignition switch RUN position (12V on both RUN and RUN/ACC inputs)

Rear window defrost switch (momentary contact to ground when switch is pressed)
Feature outputs:
Rear window defrost relay control (grounded when activated, open circuit when deactivated)

Glass, Frames and Mechanisms
Special Tool(s)
Flex Probe Kit

300-NUD105-R025DE or equivalent

Test Light
SGT27000 or equivalent 250-300 mA
incandescent bulb test lamp
and integrated diagnostic system (IDS)
software with appropriate adapters, or
One-Touch Up/Down, Front Windows
NOTE: On Expedition, only the LF window has one-touch up/down feature, however functionality is
identical to Navigator LF window.
NOTE: The LF and RF window motors are not on the multiplex link.
The LF and RF window motors have 8 pins and contain integral electronics. The master window control
switch sends 3 separate signals to the LF or RF window motor (the passenger window control switch sends 3
separate signals to the RF window motor only): up, down and auto. The master window control switch or
passenger window control switch provides a 12-volt signal to the motor to request an up or down operation.
When auto up or auto down are requested, the window control switch provides a 12-volt signal on the up or
down line and a ground signal on the auto line simultaneously. The up, down and auto contacts are floating
within the front control switches (LF, RF) when the switches are in the neutral position. The LF and RF
window motors pull the up and down inputs to ground and the auto input to 12 volts when the wire harness is
connected to the motor and signals are not being provided by the window switches. The up, down and auto
feeds to the motor are all low current.
The window motor plastic pinion gear is mated to the drum housing of a dual rail drum and cable window
regulator. The motor is attached to the drum housing (plastic) by 3 screws. The motor uses internal Hall-effect
sensor feedback coupled to the microprocessor to determine window position and operate the window. If the
Hall-effect pulses are not being received by the microprocessor, the motor will run for approximately
one-tenth second each switch press. The motor contains a thermal breaker to protect the motor windings from
overcurrent/overtemperature operation. Continued successive operation of the motor will cause the thermal
breaker to open, causing a loss of function until the motor cools.
The window motor operates with the ignition switch in the RUN/ACC positions only (and delayed accessory)
and is sensed via the delayed accessory input. The motor is supplied with B+ power and draws a key-off load

of approximately three-fourths mA. All of the high current required to move the window is supplied through
the B+ and motor ground inputs. The loss of motor ground will cause this system to become inoperative. For
correct functionality, both power feeds and the ground feed must be intact at the motor.
During an auto up or auto down function, movement of the window can be stopped by actuating the switch to
any position (up, down, auto up, auto down). The switch must then be released before the window will carry
out the next commanded movement.
When an obstacle has been detected in the window opening as the window is moving upward, the window
will automatically reverse direction and move toward the fully open position (in both up and one-touch up
modes). This is known as "bounce-back". Once the window stops at its bounce-back position, and within 2
seconds the switch is released, then held in the auto up position, the window will travel up with no
bounce-back protection (security override). If the switch is released before the window reaches fully closed,
the window will stop with bounce-back automatically re-enabled for the next window up movement. If the
ignition switch is turned to OFF or START (without delayed accessory), the window will stop. The only
exception is when an obstacle is detected while delayed accessory is lost. In this case the window will bounce
back, then stop. Ice, contaminant buildup and environmentally induced tight spots in the window seals are all
possible uses for the security override feature.
If an obstruction occurs between 4 mm (0.15 in) and 200 mm (7.87 in) of window opening, the bounce-back
position will be 250 mm (9.84 in) of window opening. If an obstruction occurs at a position greater than 200
mm (7.87 in) of window opening, the bounce-back position will be 50 mm (1.96 in) below where the
obstruction occurred.
The LF and RF window motor will retain its initialization (memory) if power (B+) is removed while the
window is not in motion. If power (B+) is disconnected from the LF or RF window motor while the window
is in motion, the motor will enter position recovery mode when power is restored (auto up and auto down
functions are disabled). Position recovery mode allows down (and up) movement of the window until the
window motor stalls the window glass in the full DOWN position. If no internal or external faults are present,
the motor will automatically resume normal (full) operation.
The master window control switch and passenger window control switch are supplied with illumination power
and illumination ground inputs used to illuminate the switch when the headlamp switch is turned to the PARK
or ON position (the AUTOLAMP position may also energize this input). These switch inputs do not directly
affect operation of the LF or RF window. The master window control switch and passenger window control
switch use the delayed accessory power input which is transferred to the up or down outputs via closing of a
switch contact. The master window control switch and passenger window control switch each have separate
ground switch inputs which are transferred to the auto output via closing of a switch contact. If the delayed
accessory feed to the window control switch is missing, none of the windows will function. If the master
window control switch ground signal is missing, the auto functions will be inoperative and the LR and RR
windows will also be inoperative. The RF window auto functions will still operate correctly from the
passenger window control switch as long as the ground feed to that switch is present.
If the window control switch, or its associated wiring, develops an open circuit, that function will become
inoperative. If the up contact or associated wiring develops an open circuit, the window will only move down
or one-touch down. If the down contact or associated wiring develops an open circuit, the window will only
move up or one-touch up. If the auto contact or associated wiring develops an open circuit, the window will
only move up or down.
The window motor will suspend window operation if a switch error exists. A switch error is defined as up and
down, auto without up or down, or up and down and auto energized at the same time. The window will appear
to be inoperative if a switch error is present.
A new LF or RF window motor will not function in one-touch up or one-touch down mode prior to

initialization. The motor will respond to an up or down switch actuation only and bounce-back is disabled. If
the switch is actuated to the auto UP or auto DOWN position and released, window movement will stop when
the up or down contact in the master window control switch or passenger window control switch is released.
If the window motor is removed from the window regulator drum housing, or if a new window motor is
installed, the window motor must be initialized. Refer to Window Motor Initialization in the General
Procedures portion of this section.
The window motor will automatically adjust to system changes throughout its life: changes in seal drag and
slight changes in the fully OPEN position will occur and are automatically compensated for. Once initialized,
for the most part, the window motor will soft stall into the lower position contributing to extended durability
of the system. If the window does not seal completely in the full UP position, the window switch can be
actuated to the UP position and the window will be energized long enough to fully seal. If the window does
not travel fully down, the window switch can be activated to the DOWN position and the window will be
energized long enough to travel to the full DOWN position. In both cases, the new positions will be learned.
Rear Window Defrost
When the rear window defrost switch is pressed, the HVAC module will activate the rear window defrost
relay located in the Battery Junction Box (BJB). When the rear window defrost relay is active, the rear
window defrost grid will be energized.
1. Verify the customer concern by operating the power window system.
2. Visually inspect for obvious signs of mechanical and electrical damage. Refer to the following chart:
Window regulator Battery Junction Box (BJB) fuse(s):

assembly 51 (40A)
Window glass 52 (10A)
Window control Smart Junction Box (SJB) circuit breaker 47
switch (30A)
Accessory delay relay
Rear window defrost relay
SJB fuse(s):
1 (30A)
4 (30A)
41 (15A)
Circuitry
Window control switch

4. NOTE: The Navigator (LF and RF) and Expedition (LF) window motors are not on the multiplex
link.
NOTE: Make sure to use the latest scan tool software release.

6. NOTE: The Smart Junction Box (SJB) may also be identified as the Generic Electronic Module
(GEM).
If the scan tool does not communicate with the vehicle:

refer to Section 418-00 to diagnose no response from the SJB .

418-00 .
(CMDTCs).
8. Clear the CMDTCs and carry out the self-test diagnostics for the SJB .
9. If the DTCs retrieved are related to the concern, go to Smart Junction Box (SJB) DTC Chart. For all
other DTCs, refer to Section 419-10 .
DTC Chart

B1302 Accessory Delay Relay Coil Circuit If the accessory delay is always on, GO to
Failure Pinpoint Test L .
If the accessory delay is inoperative, GO to

Pinpoint Test K .
B1304 Accessory Delay Relay Coil Circuit Short GO to Pinpoint Test K .
to Battery
All Other - REFER to the Master DTC Chart in Section
DTCs 419-10 .

Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test A: A Single Power Window is Inoperative - LF
Refer to Wiring Diagrams Cell 100 , Power Windows for schematic and connector information.
Normal Operation
Under normal operation, the LF power window motor microprocessor receives power at all times through
circuit SBP01 (RD) and from the accessory delay relay through circuit CBP41 (BU). Ground is provided at all
times through circuit GD143 (BK/VT). The master window control switch provides voltage input to the
power window motor microprocessor through circuit CP0 (YE/VT) to operate the driver window down, and
voltage input through circuit CPW11 (BU/GY) to operate the driver window up.

Fuse(s)
Front door window regulator motor
PINPOINT TEST A: A SINGLE POWER WINDOW IS INOPERATIVE - LF

A1 CHECK THE POWER TO THE
WINDOW MOTOR
Yes
Disconnect: LF Window Power
Window Motor C540. No
Measure the voltage between LF power VERIFY the Smart Junction Box (SJB) fuse 1 (30A) is
window motor C540-3, circuit SBP01 OK. If OK, REPAIR circuit SBP01 (RD) for an open.
(RD), harness side and ground. DE-INITIALIZE, then INIALIZE the LF power
window motor. REFER to Window Motor Initialization
in this section. TEST the system for normal operation.
If not OK, REFER to the Wiring Diagrams manual to

identify the possible causes of the circuit short.
REPAIR the circuit. DE-INITIALIZE, then
INITIALIZE the LF power window motor. REFER to
Window Motor Initialization in this section. TEST the


A2 CHECK THE LF WINDOW MOTOR
DELAYED ACCESSORY FEED
Yes
Measure the voltage between LF power
window motor C540-2, circuit CBP41 No
(BU), harness side and ground. VERIFY SJB fuse 41 (15A) is OK. If OK, REPAIR
circuit CPB41 (BU) for an open. DE-INITIALIZE,
then INITIALIZE the LF power window motor.
REFER to Window Motor Initialization in this section.

INITIALIZE the LF power window motor. REFER to
Window Motor Initialization in this section. TEST the
A3 CHECK THE LF MOTOR GROUND
Yes
Ignition OFF. For Expedition, GO to A4 . For Navigator, GO to A5 .
Open the front door to disable delayed
accessory power. No
Measure the resistance between LF REPAIR circuit GD143 (BK/VT) for an open.
power window motor C540-8, circuit DE-INITIALIZE, then INITIALIZE the LF power
GD143 (BK/VT), harness side and window motor. REFER to Window Motor Initialization
ground. in this section. TEST the system for normal operation.

A4 CHECK THE FRONT WINDOW
SWITCH TO LF MOTOR FEEDS
PINPOINT TEST A: A SINGLE POWER WINDOW IS INOPERATIVE - LF 572

Disconnect: Master Window Control Yes

Switch C504A. GO to A6 .
Measure the resistance between LF
power window motor C540, harness No
side and master window control switch REPAIR circuit CPW11 (BU/GY), CPW10 (YE/VT)
C504A, harness side using the or CPW29 (VT/GY) for an open. DE-INITIALIZE,
following chart: then INITIALIZE the LF power window motor.
REFER to Window Motor Initialization in this section.
Master
LF Power Window
Window Control
Motor Circuit Switch
C540-7 CPW11 C504A-5
(BU/GY)
C540-4 CPW10 C504A-1
(YE/VT)
C540-6 CPW29 C504A-7
(VT/GY)

A5 CHECK THE FRONT WINDOW
SWITCH TO LF MOTOR FEEDS
Yes
Disconnect: Master Window Control GO to A6 .
Switch C535A.
Measure the resistance between LF No
power window motor C540, harness REPAIR circuit CPW11 (BU/GY), CPW10 (YE/VT)
side and master window control switch or CPW29 (VT/GY) for an open. DE-INITIALIZE,
C535A, harness side using the then INITIALIZE the LF power window motor.
following chart: REFER to Window Motor Initialization in this section.
Master
LF Power Window
Window Control
C540-7 CPW11 C535A-4
(BU/GY)
C540-4 C535A-7
PINPOINT TEST A: A SINGLE POWER WINDOW IS INOPERATIVE - LF 573

CPW10
(YE/VT)
C540-6 CPW29 C535A-8
(VT/GY)

A6 CHECK THE MASTER WINDOW
CONTROL SWITCH
Yes
Carry out the window control switch INSTALL a new LF power window motor. REFER to
component test. Window Regulator Motor - Front Door in this section.
INITIALIZE the LF door window motor. REFER to
Refer to Wiring Diagrams Cell 149 for Window Motor Initialization in this section. TEST the
component testing. system for normal operation.
Did the window control switch pass
the component test? No
INSTALL a new master window control switch.
REFER to Window Control Switch in this section.
Pinpoint Test B: A Single Power Window is Inoperative - RF, Expedition
Normal Operation
Under normal operation, the RF window control switch receives power from the master window control
switch through circuit CPW30 (GY/YE). The RF window control switch provides power to the power
window motor through circuit CPW20 (WH/OG) and ground through circuit CPW19 (VT) to operate the
passenger front window up, and power through circuit CPW19 (VT) and ground through circuit CPW20
(WH/OG) to operate the passenger front window down.
When operating the passenger front window using the master window control switch, power is sent to the RF
window control switch through circuit CPW12 (GN/OG) and ground through circuit CPW13 (BN/YE) to
operate the passenger front window up, and power through circuit CPW13 (BN/YE) and ground through
circuit CPW12 (GN/OG) to operate the passenger front window down.


PINPOINT TEST B: A SINGLE POW WINDOW IS INOPERATIVE - RF, EXPEDITION

B1 CHECK THE VOLTAGE TO THE PASSENGER WINDOW
REGULATOR CONTROL SWITCH
Yes
Disconnect: RF Window Control Switch C624. GO to B2 .
Ignition ON.
NOTE: Set the window lock switch to the UNLOCK position. No
Measure the voltage between RF window control switch REPAIR circuit CPW30
C624-3, circuit CPW30 (GY/YE), harness side and ground. (GY/YE) for an open. TEST
operation.

B2 CHECK CIRCUITS CPW13 (BN/YE) AND CPW12 (GN/OG)
FOR CONTINUITY TO GROUND
Yes
Measure the resistance between ground and RF window control
switch C624-1, circuit CPW13 (BN/YE), harness sidend ground; No
and between C624-6, circuit CPW12 (GN/OG), harness side and GO to B3 .
ground.

B3 CHECK CIRCUITS CPW13 (BN/YE) AND CPW12 (GN/OG)
FOR AN OPEN
Yes
Disconnect: Master Window Control Switch C504A. INSTALL a new master
Measure the resistance between master window control switch window control switch.
C504A-4, circuit CPW13 (BN/YE), harness side and RF REFER to Window Control
window control switch C624-1, circuit CPW13 (BN/YE), Switch in this section. TEST
harness side. the system for normal
operation.
PINPOINT TEST B: A SINGLE POW WINDOW IS INOPERATIVE - RF, EXPEDITION 575

No
REPAIR circuit CPW13
(BN/YE) or CPW12 (GN/OG)
for an open. TEST the system
Measure the resistance between master window control switch

C504A-8, circuit CPW12 (GN/OG), harness side and RF
window control switch C624-6, circuit CPW12 (GN/OG),
harness side.

B4 CHECK THE RF POWER WINDOW SWITCH
Yes
Ignition ON. INSTALL a new RF window
Connect a fused jumper wire between C624-1, circuit CPW13 regulator control switch.
(BN/YE), harness side and C624-2, circuit CPW19 (VT), REFER to Window Control
harness side; and a second fused jumper wire between C624-3, Switch in this section. TEST
circuit CPW30 (GY/YE), harness side and C624-5, circuit the system for normal
CPW20 (WH/OG), harness side. The window should operate in operation.
the upward direction.
No
GO to B5 .
Connect a fused jumper wire between C624-6, circuit CPW12

(GN/OG), harness side and C624-5, circuit CPW20 (WH/OG),
harness side; and a second fused jumper wire between C624-3,
circuit CPW30 (GY/YE), harness side and C624-2, circuit
CPW19 (VT), harness side. The window should operate in the
downward direction.
PINPOINT TEST B: A SINGLE POW WINDOW IS INOPERATIVE - RF, EXPEDITION 576

Does the window operate correctly?

B5 CHECK CIRCUITS CPW19 (VT) AND CPW20 (WH/OG)
FOR AN OPEN
Yes
Ignition OFF. INSTALL a new RF window
Disconnect: RF Window Motor C608. regulator motor. REFER to
Measure the resistance between RF window control switch Window Regulator Motor -
C624-2, circuit CPW19 (VT), harness side, and RF window Front Door in this section.
motor C608-1, circuit CPW19 (VT), harness side. TEST the system for normal
operation.
No
REPAIR circuit CPW19 (VT)
or CPW20 (WH/OG) for an
open. TEST the system for
normal operation.
Measure the resistance between RF window control switch

C624-5, circuit CPW20 (WH/OG), harness side and RF window
motor C608-2, circuit CPW20 (WH/OG), harness side.
Pinpoint Test C: A Single Power Window is Inoperative - RF, Navigator
Refer to Wiring Diagrams Cell 100 , PoWindows for schematic and connector information.
Normal Operation
Under normal operation, the RF power window motor microprocessor receives power at all times through
circuit SBP04 (GN/RD) and from the accessory delay relay through circuit CBP41 (BU). Ground is provided
at all times through circuit GD138 (BK/WH). The master window control switch or passenger window control
switch provides a voltage input to the power window motor microprocessor through circuit CPW19 (VT) to
operate the RF window down, and voltage input through circuit CPW20 (WH/OG) to operate the RF window
up.

Fuse(s)
PINPOINT TEST C: A SINGLE POWER WINDOW IS INOPERATIVE - RF, NAVIGATOR

C1 CHECK THE MASTER WINDOW CONTROL
SWITCH OPERATION
Yes
Attempt to operate the RH window using the GO to C7 .
master window control switch.
Does the RH window operate when using the No
master window control switch? GO to C2 .
C2 CHECK THE POWER TO THE WINDOW
MOTOR
Yes
Disconnect: RF Window Power Window Motor
C646. No
Measure the voltage between RF power window VERIFY the Smart Junction Box (SJB) fuse 4
motor C646-3, circuit SBP04 (GN/RD), harness (30A) is OK. If OK, REPAIR circuit SBP04
side and ground. (GN/RD) for an open. DE-INITIALIZE, then
INITIALIZE the RF power window motor.
REFER to Window Motor Initialization in
this section. TEST the system for normal
operation.
If not OK, REFER to the Wiring Diagrams

circuit short. REPAIR the circuit.
DE-INITIALIZE, then INITIALIZE the RF
power window motor. REFER to Window
Motor Initialization in this section. TEST the
C3 CHECK THE RF WINDOW MOTOR
DELAYED ACCESSORY FEED
Yes
Ignition ON. GO to C4 .
Measure the voltage between RF power window
motor C646-2, circuit CBP41 (BU), harness side No
and ground. VERIFY SJB fuse 41 (15A) is OK. If OK,
REPAIR circuit CBP41 (BU) for an open.
PINPOINT TEST C: A SINGLE POWER WINDOW IS INOPERATIVE - RF, NAVIGATOR 578


C4 CHECK THE RF MOTOR GROUNDS
Yes
Open the front door to disable delayed accessory
power. No
Measure the resistance between RF power REPAIR circuit GD138 (BK/WH) for an
window motor C646-8, circuit GD138 (BK/WH), open. DE-INITIALIZE, then INITIALIZE the
harness side and ground. RF power window motor. REFER to Window

C5 CHECK THE FRONT WINDOW SWITCH TO
RF MOTOR FEEDS
Yes
Disconnect: Master Window Control Switch GO to C6 .
C535A.
Measure the resistance between RF power No
window motor C646, harness side and master REPAIR circuit CPW20 (WH/OG), CPW19
window control switch C535A, harness side (VT) or CPW31 (GN/WH) for an open.
using the following chart: DE-INITIALIZE, then INITIALIZE the RF
RF Power
Window Master Window
Motor Circuit Control Switch
C646-7 CPW20 C535A-5
(WH/OG)
C646-4 CPW19 (VT) C535A-2
C646-6 CPW31 C535A-1
(GN/WH)


C6 CHECK THE MASTER WINDOW CONTROL
SWITCH
Yes
Carry out the master window control switch INSTALL a new RF power window motor.
component test. REFER to Window Regulator Motor - Front
Door in this section. INITIALIZE the RF door
Refer to Wiring Diagrams Cell 149 for window motor. REFER to Window Motor
component testing. Initialization in this section. TEST the system
Did the master window control switch pass the for normal operation.
component test?
No
INSTALL a new master window control
switch. REFER to Window Control Switch in
this section. TEST the system for normal
operation.
C7 CHECK CIRCUIT CBP41 (BU) FOR AN OPEN
Yes
Disconnect: Passenger Window Control Switch GO to C8 .
C648.
Ignition ON. No
Measure the voltage between passenger window REPAIR circuit CBP41 (BU) for an open.
control switch C648-2, circuit CBP41 (BU), DE-INITIALIZE, then INITIALIZE the RF
harness side and ground. power window motor. REFER to Window

C8 CHECK CIRCUIT GD138 (BK/WH) FOR AN
OPEN
Yes
Measure the resistance between passenger front
window control switch C648-6, circuit GD138 No
(BK/WH), harness side and ground. REPAIR circuit GD138 (BK/WH) for an
open. DE-INITIALIZE, then INITIALIZE the
RF power window motor. REFER to Window


C9 CHECK THE FRONT WINDOW SWITCH TO
RF MOTOR FEEDS
Yes
Measure the resistance between RF power INSTALL a new passenger window control
window motor C646, harness side and passenger switch. REFER to Window Control Switch in
window control switch, harness side using the this section. TEST the system for normal
following chart: operation.
No
REPAIR circuit CPW20 (WH/OG), CPW19
(VT) or CPW31 (GN/WH) for an open.
Passenger RF Power DE-INITIALIZE, then INITIALIZE the RF
Window Control Window power window motor. REFER to Window
Switch Circuit Motor Motor Initialization in this section. TEST the
C648-3 CPW20 C646-7 system for normal operation.
(WH/OG)
C648-5 CPW19 C646-4
(VT)
C648-4 CPW31 C646-6
(GN/WH)
Is the resistance less than 5 ohms on all

circuits?
Pinpoint Test D: A Single Power Window is Inoperative - LR or RR, Expedition
Normal Operation
Under normal operation, the LR and RR window control switches receive power from the master window
control switch through circuit CPW30 (GY/YE). The LR window control switch provides power to the LR
power window motor through circuit CPW21 (BN) and ground through circuit CPW22 (GN/VT) to operate
the LR window down and power through circuit CPW22 (GN/VT) and ground through circuit CPW21 (BN)
to operate the LR window up. The RR window control switch provides power to the RR power window motor
through circuit CPW23 (GY) and ground through circuit CPW24 (WH/VT) to operate the RR wind down and

power through circuit CPW24 (WH/VT) and ground through circuit CPW23 (GY) to operate the RR window
up.
When operating the LR window using the master window control switch, power is sent to the LR window
control switch through circuit CPW15 (YE) and ground through circuit CPW16 (BU/OG) to operate the LR
window down and power through circuit CPW16 (BU/OG) and ground through circuit CPW15 (YE) to
operate the LR window up. When operating the RR window using the master window control switch, power is
sent to the RR window control switch through circuit CPW17 (BN/GN) and ground through circuit CPW18
(GY/VT) to operate the RR window down and power through circuit CPW18 (GY/VT) and ground through
circuit CPW17 (BN/GN) to operate the RR window up.

Rear door window regulator motor
PINPOINT TEST D: A SINGLE POWER WINDOW IS INOPERATIVE - LR OR RR, EXPEDITION

D1 CHECK THE VOLTAGE TO THE LR OR RR WINDOW
CONTROL SWITCH
Yes
Disconnect: Inoperative Rear Window Control Switch C701 (LR) GO to D2 .
or C801 (RR).
Ignition ON. No
NOTE: Set the window lock switch to the UNLOCK position. REPAIR circuit CPW30
Measure the voltage between the inoperative rear window switch (GY/YE) for an open. TEST
C701-3 or C801-3, circuit CPW30 (GY/YE), harness side and the system for normal
ground. operation.

D2 CHECK THE GROUNDS TO THE INOPERATIVE REAR
WINDOW CONTROL SWITCH
Yes
Measure the resistance between the inoperative rear window
switch connector and ground. No
For an inoperative LR window, measure the resistance GO to D3 .
between LR window switch C701-1, circuit CPW17
(BN/GN), harness side and ground; and between C701-6,
PINPOINT TEST D: A SINGLE POWER WINDOW IS INOPERATIVE - LR OR RR, EXPEDITION582

circuit CPW18 (GY/VT), harness side and ground.

For an inoperative RR window, measure the resistance
between RR window switch C801-1, circuit CPW17
(BN/GN), harness side and ground; and between C801-6,
circuit CPW18 (GY/VT), harness side and ground.

D3 CHECK THE CIRCUITS TO THE INOPERATIVE REAR
WINDOW CONTROL SWITCH FOR AN OPEN
Yes
Ignition OFF. INSTALL a new master
Disconnect: Master Window Control Switch C504B. window control switch.
For an inoperative LR window, measure the resistance between REFER to Window Control
master window control switch C504B, harness side and LR Switch in this section. TEST
window control switch C701, harness side using the following the system for normal
chart: operation.
No
REPAIR circuit CPW15
(YE), CPW16 (BU/OG),
Master Window LR Window Control CPW17 (BN/GN) or
Control Switch Circuit Switch CPW18 (GY/VT) for an
C504B-1 CPW15 (YE)/ C701-1 open. TEST the system for
normal operation.
CPW17
(BN/GN)
C504B-5 CPW16 C701-6
(BU/OG)/
CPW18
(GY/VT)
For an inoperative RR window, measure the resistance between

master window control switch C504B, harness side and RR
window control switch C801, harness side using the following
chart:

Master Window RR Window Control

Control Switch Circuit Switch
C504B-4 CPW17 C801-1
(BN/GN)
C504B-8 CPW18 C801-6
(GY/VT)

D4 CHECK THE INOPERATIVE WINDOW CONTROL SWITCH
Yes
Connect: Master Window Control Switch C504B. INSTALL a new rear
Ignition ON. window control switch.
Connect fused jumper wires between the inoperative power REFER to Window Control
window switch as shown. Switch in this section. TEST
For an inoperative LR window, connect a fused jumper the system for normal
wire between LR window control switch C701-5, circuit operation.
CPW24 (WH/VT), harness side and C701-3, circuit
CPW30 (YE), harness side; and a second fused jumper No
wire between C701-2, circuit CPW23 (GY), harness side GO to D5 .
and C701-1, circuit CPW17 (BN/GN), harness side. The
window should operate in the upward direction.
For an inoperative RR window, connect a fused jumper
wire between RR window control switch C801-5, circuit
CPW30 (YE), harness side; and a second fused jumper
wire between C801-2, circuit CPW23 (GY), harness side
and C801-1, circuit CPW17 (BN/GN), harness side. The
Connect fused jumper wires between the inoperative power

window switch as shown.
For an inoperative LR window, connect a fused jumper
wire between LR window control switch C701-5, circuit

CPW18 (GY/VT), harness side; and a second fused jumper

and C701-3, circuit CPW30 (GY/YE), harness side. The
window should operate in the downward direction.
CPW18 (GY/VT), harness side; and a second fused jumper
and C801-3, circuit CPW30 (GY/YE), harness side. The

D5 CHECK POWER WINDOW MOTOR CIRCUITS
Yes
Ignition OFF. INSTALL a new rear
Disconnect: Inoperative Power Window Motor C703 (LR) or C803 window regulator motor.
(RR). REFER to Window
Measure the resistance between inoperative window control switch Regulator Motor - Rear
and the inoperative window motor. Door in this section. TEST
For an inoperative LR window, measure the resistance the system for normal
between LR window control switch C701-5, circuit operation.
CPW24 (WH/VT), harness side and LR power window
motor C703-2, circuit CPW24 (WH/VT), harness side. No
For an inoperative RR window, measure the resistance REPAIR the circuit(s) for an
between RR window control switch C801-5, circuit open. TEST the system for
CPW24 (WH/VT), harness side and RR power window normal operation.
motor C803-2, circuit CPW24 (WH/VT), harness side.
Measure the resistance between inoperative window control switch

and the inoperative window motor.
For an inoperative LR window, measure the resistance
between LR window control switch C701-2, circuit
CPW23 (GY), harness side and LR power window motor
C703-1, circuit CPW23 (GY), harness side.
between RR window control switch C801-2, circuit
CPW23 (GY), harness side and RR power window motor


Pinpoint Test E: A Single Power Window is Inoperative - LR or RR, Navigator
Normal Operation
Under normal operation, the master window control switch receives power for the LR and RR window
circuits through circuit CBP47 (GN/BU). The LR and RR window control switches receive power from the
master window control switch through circuit CPW30 (GY/YE). The LR window control switch provides
power to the LR power window motor through circuit CPW21 (BN) and ground through circuit CPW22
(GN/VT) to operate the LR window down, and power through circuit CPW22 (GN/VT) and ground through
circuit CPW21 (BN) to operate the LR window up. The RR window control switch provides power to the RR
power window motor through circuit CPW23 (GY) and ground through circuit CPW24 (WH/VT) to operate
the RR window down, and power through circuit CPW24 (WH/VT) and ground through circuit CPW23 (GY)
to operate the RR window up.
When operating the LR window using the master window control switch, power is sent to the LR window
control switch through circuit CPW15 (YE) and ground through circuit CPW16 (BU/OG) to operate the LR
window down, and power through circuit CPW16 (BU/OG) and ground through circuit CPW15 (YE) to
operate the LR window up. When operating the RR window using the master window control switch, power is
sent to the RR window control switch through circuit CPW17 (BN/GN) and ground through circuit CPW
(GY/VT) to operate the RR window down, and power through circuit CPW18 (GY/VT) and ground through
circuit CPW17 (BN/GN) to operate the RR window up.

Fuse
Rear door window regulator motor
PINPOINT TEST E: A SINGLE POWER WINDOW IS INOPERATIVE - LR OR RR, NAVIGATOR

E1 CHECK CIRCUIT CBP47 (GN/BU) FOR VOLTAGE

Disconnect: Master Window Control Switch C535B. Yes

Ignition ON. GO to E2 .
Measure the voltage between master window control switch
C535B-3, circuit CBP47 (GN/BU), harness side and ground. No
VERIFY the Smart Junction
Box (SJB) circuit breaker 47
(30A) is OK. If OK, PAIR
circuit CBP47 (GN/BU) for
an open. TEST the system for
normal operation.
If not OK, REFER to the

Wiring Diagrams manual to
identify the possible causes
of the circuit short. REPAIR
the circuit. TEST the system
E2 CHECK THE VOLTAGE TO THE LR OR RR WINDOW
CONTROL SWITCH
Yes
Connect: Master Window Control Switch C535B. GO to E3 .
Disconnect: Inoperative Rear Window Control Switch C701 (LR)
or C801 (RR). No
Ignition ON. REPAIR circuit CPW30
NOTE: Set the window lock switch to the UNLOCK position. (GY/YE) for an open. TEST
Measure the voltage between the inoperative rear window control the system for normal
switch connector and ground. operation.
For an inoperative LR window, measure the voltage
CPW30 (GY/YE), harness side and ground.
For an inoperative RR window, measure the voltage
CPW30 (GY/YE), harness side and ground.

E3 CHECK THE GROUNDS TO THE INOPERATIVE REAR
WINDOW CONTROL SWITCH
Yes
Measure the resistance between the inoperative window control
switch and ground. No
For an inoperative LR window, measure the resistance GO to E4 .
CPW17 (BN/GN), harness side and ground; and between
C701-6, circuit CPW18 (GY/VT), harness side and
ground.
PINPOINT TEST E: A SINGLE POWER WINDOW IS INOPERATIVE - LR OR RR, NAVIGATOR587


CPW17 (BN/GN), harness side and ground; and between
C801-6, circuit CPW18 (GY/VT), harness side and
ground.

E4 CHECK THE CIRCUITS TO THE INOPERATIVE REAR
WINDOW CONTROL SWITCH FOR AN OPEN
Yes
Ignition OFF. INSTALL a new master
Disconnect: Master Window Control Switch C535B. window control switch.
For an inoperative LR window, measure the resistance between REFER to Window Control
master window control switch C535B, harness side and LR Switch in this section. TEST
window control switch C701, harness side using the following the system for normal
chart: operation.
No
REPAIR the circuit(s) for an
Master Window LR Window Control normal operation.
C535B-1 CPW15 (YE)/ C701-1
CPW17
(BN/GN)
C535B-2 CPW16 C701-6
(BU/OG)/
CPW18
(GY/VT)
For an inoperative RR window, measure the resistance between

master window control switch C535B, harness side and RR
window control switch C801, harness side using the following
chart:

Master Window RR Window Control

C535B-7 CPW17 C801-1
(BN/GN)
C535B-8 CPW18 C801-6
(GY/VT)

E5 CHECK THE INOPERATIVE WINDOW CONTROL SWITCH
Yes
Connect: Master Window Control Switch C535B. INSTALL a new rear
Ignition ON. window regulator control
Connect fused jumper wires between the inoperative power switch. REFER to Window
window switch as shown. Control Switch in this
For an inoperative LR window, connect a fused jumper section. TEST the system for
wire between LR window control switch C701-1, circuit normal operation.
CPW17 (BN/GN), harness side and C701-2, circuit
CPW23 (GY), harness side; and a second fused jumper No
wire between C701-5, circuit CPW24 (WH/VT), harness GO to E6 .
side and C701-3, circuit CPW30 (YE), harness side. The
CPW17 (BN/GN), harness side and C801-2, circuit
CPW23 (GY) harness side; and a second fused jumper
wire between C801-5, circuit CPW24 (WH/VT), harness
side and C801-3, circuit CPW30 (YE), harness side. The
Connect fused jumper wires between the inoperative power

window switch as shown.
For an inoperative LR window, connect a fused jumper
wire between LR window control switch C701-3, circuit
CPW30 (YE), harness side and C701-2, circuit CPW23

(GY), harness side; and a second fused jumper wire

between C701-5, circuit CPW24 (WH/VT), harness side
and C701-6, circuit CPW18 (GY/VT), harness side. The
CPW30 (YE), harness side and C801-2, circuit CPW23
(GY), harness side; and a second fused jumper wire
between C801-5, circuit CPW24 (WH/VT), harness side
and C801-6, circuit CPW18 (GY/VT), harness side. The

E6 CHECK THE POWER WINDOW MOTOR CIRCUITS
Yes
Ignition OFF. INSTALL a new window
Disconnect: Inoperative Power Window Motor C703 (LR) or motor. REFER to Window
C803 (RR). Regulator Motor - Front Door
Measure the resistance between inoperative window control in this section. TEST the
switch and the inoperative window motor. system for normal operation.
between LR window control switch C701-5, circuit No
CPW24 (WH/VT), harness side and LR power window REPAIR circuit CPW21
motor C703-2, circuit CPW24 (WH/VT), harness side. (BN), CPW22 (GN/VT),
For an inoperative RR window, measure the resistance CPW23 (GY) or CPW24
between RR window control switch C801-5, circuit (WH/VT) for an open. TEST
CPW24 (WH/VT), harness side and RR power window the system for normal
motor C803-2, circuit CPW24 (WH/VT), harness side. operation.
Measure the resistance between inoperative window control

switch and the inoperative window motor.
CPW23 (GY), harness side and LR power window motor
CPW23 (GY), harness side and RR power window motor

Pinpoint Test F: The One-Touch Up/Down Feature is Inoperative - LF
Normal Operation
Under normal operation, the LF power window motor microprocessor receives powt all times through circuit
SBP01 (RD) and from the accessory delay relay through circuit CBP41 (BU). Ground is provided at all times
through circuit GD143 (BK/VT). The master window control switch provides voltage input to the power
window motor microprocessor through circuit CPW10 (YE/VT) to operate the driver window down, and
voltage input through circuit CPW11 (BU/GY) to operate the driver window up. To operate the one-touch
feature, the master window control switch provides a ground input to the LF power window motor
microprocessor through circuit CPW29 (VT/GY) in addition to the up or down request.

Fuse(s)
PINPOINT TEST F: THE ONE-TOUCH UP/DOWN FEATURE IS INOPERATIVE - LF

F1 CHECK FOR POWER (B+) LOSS DURING LF
WINDOW OPERATION
Yes
Verify if power (B+) was lost during LF window LOWER the LF window to the full OPEN
operation. position. MAKE SURE the window glass
Was power (B+) lost while LF window was in stalls in the full DOWN position for at least a
operation? half second. Normal functionality should
resume. TEST the system for normal
operation.
No
GO to F2 .
F2 INITIALIZE THE LF MOTOR
Yes
Repair is complete. TEST the system for

Carry out the LF window motor initialization normal operation.

procedure. Refer to Window Motor Initialization
in this section. No
Are the one-touch up/down functions operating GO to F3 .
correctly?
F3 CHECK THE MASTER WINDOW CONTROL
SWITCH
Yes
Carry out the front window switch component For Expedition, GO to F4 . For Navigator,
test. GO to F5 .
Refer to Wiring Diagrams Cell 149 for component No

testing. INSTALL a new master window control
Did the front window switch pass the switch. REFER to Window Control Switch
component test? in this section. TEST the system for normal
operation.
F4 CHECK THE FRONT WINDOW SWITCH TO
LF MOTOR FEEDS
Yes
power. No
Disconnect: Master Power Window Control REPAIR circuit CPW11 (BU/GY), CPW10
Switch C504A. (YE/VT) or CPW29 (VT/GY) for an open.
Disconnect: LF Power Window Motor C540. DE-INITIALIZE, then INITIALIZE the LF
Measure the resistance between LF power window power window motor. REFER to Window
motor C540, harness side and master window Motor Initialization in this section. TEST the
control switch C504A, harness side using the system for normal operation.
following chart:
Master
Window
LF Power Control
Window Motor Circuit Switch
C540-7 CPW11 C504A-5
(BU/GY)
C540-4 CPW10 C504A-1
(YE/VT)
C540-6 CPW29 C504A-7
(VT/GY)
PINPOINT TEST F: THE ONE-TOUCH UP/DOWN FEATURE IS INOPERATIVE - LF 592


F5 CHECK THE FRONT WINDOW SWITCH TO
LF MOTOR FEEDS
Yes
power. No
Disconnect: Master Power Window Control REPAIR circuit CPW11 (BU/GY), CPW10
Switch C535A. (YE/VT) or CPW29 (VT/GY) for an open.
Disconnect: LF Power Window Motor C540. DE-INITIALIZE, then INITIALIZE the LF
Measure the resistance between LF power window power window motor. REFER to Window
motor C540, harness side and master window Motor Initialization in this section. TEST the
control switch C535A, harness side using the system for normal operation.
following chart:
Master
Window
LF Power Control
Window Motor Circuit Switch
C540-7 CPW11 C535A-4
(BU/GY)
C540-4 CPW10 C535A-7
(YE/VT)
C540-6 CPW29 C535A-8
(VT/GY)

F6 CHECK FOR AN INTERMITTENT GROUND
CONNECTION
Yes
Measure the resistance between LF power window
motor C540-8, circuit GD143 (BK/VT), harness No
side and ground. REPAIR circuit GD143 (BK/VT) for an
open. DE-INITIALIZE, then INITIALIZE
the LF power window motor. REFER to
Window Motor Initialization in this section.
PINPOINT TEST F: THE ONE-TOUCH UP/DOWN FEATURE IS INOPERATIVE - LF 593

Wiggle the harness while measuring the

resistances.
F7 CHECK FOR INTERMITTENT POWER
CONNECTIONS
Yes
Ignition ON. INSTALL a new LF power window motor.
Measure the voltage between LF power window REFER to Window Regulator Motor - Front
motor C540-3, circuit SBP01 (RD), harness side Door in this section. INITIALIZE the LF
and ground; and between C540-2, circuit CPB41 power window motor. REFER to Window
(BU), harness side and ground. Motor Initialization in this section. TEST the
No
VERIFY Smart Junction Box (SJB) fuses 1
(30A) and 41 (15A) are OK. If OK, REPAIR
circuit SBP01 (RD) or CPB41 (BU) for an
open. DE-INITIALIZE, then INITIALIZE
the LF power window motor. REFER to
Wiggle the harness while measuring the voltages.
DE-INITIALIZE, then INITIALIZE the LF
Pinpoint Test G: The One-Touch Up/Down Feature is Inoperative - RF, Navigator
Normal Operation
Under normal operation, the RF power window motor microprocessor receives power at all times through
circuit SBP04 (GN/RD) and from the accessory delay relay through circuit CBP41 (BU). Ground is provided
at all times through circuit GD138 (BK/WH). The master window control switch or RF window control
switch provides voltage input to the power window motor microprocessor through circuit CPW19 (VT) to
operate the RF window down, and voltage input through circuit CPW20 (WH/OG) to operate the RF window
up. To operate the one-touch feature, the master window corol switch or RF window control switch provides a
ground input to the RF power window motor microprocessor through circuit CPW31 (GN/WH) in addition to
the up or down request.

Fuse(s)
PINPOINT TEST G: THE ONE-TOUCH UP/DOWN FEATURE IS INOPERATIVE - RF, NAVIGATOR

G1 CHECK THE MASTER WINDOW
CONTROL SWITCH OPERATION
Yes
Attempt to operate the RH window in GO to G8 .
one-touch up/down mode using the master
window control switch. No
Does the RH window operate in GO to G2 .
one-touch up/down mode when using
the master window control switch?
G2 CHECK FOR POWER (B+) LOSS
DURING RF WINDOW OPERATION
Yes
Verify if power (B+) was lost during RF LOWER the RF window to the full OPEN position.
window operation. MAKE SURE the window glass stalls in the full
Was power (B+) lost while RF window DOWN position for at least a half second. Normal
was in operation? functionality should resume. TEST the system for
normal operation.
No
GO to G3 .
G3 INITIALIZE THE RF MOTOR
Yes
Carry out the RF window motor Repair is complete. TEST the system for normal
initialization procedure. Refer to Window operation.
Motor Initialization in this section.
Are the one-touch up/down functions No
operating correctly? GO to G4 .
G4 CHECK THE MASTER WINDOW
CONTROL SWITCH
Yes
Carry out the front window switch GO to G5 .
component test.
No
Refer to Wiring Diagrams Cell 149 for INSTALL a new master window control switch.
component testing. REFER to Window Control Switch in this section.
Did the master window control switch TEST the system for normal operation.
pass the component test?
G5 CHECK THE FRONT WINDOW
SWITCH TO RF MOTOR FEEDS

595
Ignition OFF. Yes

Open the front door to disable delayed GO to G6 .
accessory power.
Disconnect: Power Window Switch No
C535A. REPAIR circuit CPW20 (WH/OG), CPW19 (VT) or
Disconnect: RF Power Window Motor CPW31 (GN/WH) for an open. DE-INITIALIZE,
C646. then INITIALIZE the RF power window motor.
Measure the resistance between RF power REFER to Window Motor Initialization in this
window motor C646, harness side and section. TEST the system for normal operation.
master window control switch C535A,
harness side using the following chart:
Master
RF Power Window
Window Control
C646-7 CPW20 C535A-5
(WH/OG)
C646-4 CPW19 C535A-2
(VT)
C646-6 CPW31 C535A-1
(GN/WH)

G6 CHECK FOR AN INTERMITTENT
GROUND CONNECTION
Yes
Measure the resistance between RF power
window motor C646-8, circuit GD138 No
(BK/WH), harness side and ground. REPAIR circuit GD138 (BK/WH) for an open.
DE-INITIALIZE, then INITIALIZE the RF power
window motor. REFER to Window Motor
Initialization Initialization in this section. TEST the

596

resistances.
G7 CHECK FOR INTERMITTENT POWER
CONNECTIONS
Yes
Ignition ON. INSTALL a new RF power window motor. REFER
Measure the voltage between RF power to Window Regulator Motor - Front Door in this
window motor C646-3, circuit SBP04 section. INITIALIZE the RF power window motor.
(GN/RD), harness side and ground; and REFER to Window Motor Initialization in this
between C646-2, circuit CBP41 (BU), section. TEST the system for normal operation.
No
VERIFY SJB fuses 4 (30A) and 41 (15A) are OK. If
OK, REPAIR circuit SBP04 (GN/RD) or CBP41
(BU) for an open. DE-INITIALIZE, then
INITIALIZE the RF power window motor. REFER
to WindoMotor Initialization in this section. TEST

voltages.
INITIALIZE the RF power window motor. REFER
to Window Motor Initialization in this section. TEST
G8 CHECK THE FRONT WINDOW
SWITCH TO RF MOTOR FEEDS
Yes
Measure the resistance between RF power INSTALL a new passenger window control switch.
window motor C646, harness side and REFER to Window Control Switch in this section.
passenger window control switch C648, TEST the system for normal operation.
harness side using the following chart:
No
REPAIR circuit CPW20 (WH/OG), CPW19 (VT) or
CPW31 (GN/WH) for an open. DE-INITIALIZE,
then INITIALIZE the RF power window motor.
Passenger REFER to Window Motor Initialization in this
Window RF Power section. TEST the system for normal operation.
Control Window
Switch Circuit Motor
C648-3 CPW20 C646-7
(WH/OG)
C648-5 CPW19 C646-4
(VT)
C648-4 CPW31 C646-6
(GN/WH)

597
Is the resistance less than 5 ohms on all

circuits?
Pinpoint Test H: The Left or Right Power Window is Inoperative - Rear Vent Window
Normal Operation
Under normal operation, the quarter window control switch, quarter window close relay and quarter window
open relay receive power from the accessory delay rel through circuit CBP41 (BU). Ground is provided to the
quarter window close relay and quarter window open relay through circuit GD151 (BK/GN). Ground is
provided to the quarter window control switch through GD138 (BK/WH). The quarter window control switch
activates the quarter window open relay by supplying a ground input through circuit CPW26 (BU/BN) and
activates the quarter window close relay by supplying a ground input through circuit CPW25 (YE/BU). When
the quarter window open relay is activated, power is supplied to the LH and RH quarter window motors
through circuit CPW27 (GN) and ground through circuit CPW28 (WH/BN) through the quarter window close
relay circuit GD151 (BK/GN) to operate the quarter windows open. When the quarter window close relay is
activated, power is supplied to the LH and RH quarter window motors through circuit CPW28 (WH/BN) and
ground through circuit CPW27 (GN) through the quarter window open relay circuit GD151 (BK/GN) to
operate the quarter windows closed.

Fuse
Quarter window close relay
Quarter window open relay
Quarter window control switch
Rear quarter window regulator motor
PINPOINT TEST H: THE LEFT OR RIGHT POWER WINDOW IS INOPERATIVE - REAR VENT WINDOW

H1 CHECK THE VENT WINDOW OPERATION
Yes
Attempt to operate the vent windows while observing GO to H2 .
both LR and RR vent window operation.
Are both the LH and RH ventindows inoperative? No
GO to H8 .
H2 CHECK FOR GROUND INPUT TO THE VENT
WINDOW OPEN AND CLOSE RELAYS

Disconnect: Quarter Window Open Relay and Yes

Quarter Window Close Relay. GO to H5 .
While holding the quarter window control switch in
the close position, measure the resistance between No
quarter window close relay pin 1, circuit CPW25 GO to H3 .
(YE/BU), harness side and ground.
While holding the quarter window control switch in

the open position, measure the resistance between
quarter window open relay pin 2, circuit CPW26
(BU/BN), harness side and ground.

H3 CHECK FOR GROUND AT THE VENT WINDOW
SWITCH
Yes
Disconnect: Overhead Console Switch C930. GO to H4 .
Measure the resistance between quarter window
control switch C930-12, circuit GD138 (BK/WH), No
harness side and ground. REPAIR circuit GD138 (BK/WH) for an
open. TEST the system for normal
operation.
PINPOINT TEST H: THE LEFT OR RIGHT POWER WINDOW IS INOPERATIVE - REAR VENT 599
WINDOW

H4 CHECK CIRCUITS CPW25 (YE/BU) AND CPW26
(BU/BN) FOR AN OPEN
Yes
Measure the resistance between power vent window INSTALL a new vent power window
close relay pin 1, circuit CPW25 (YE/BU), harness switch. REFER to Window Control
side and power vent window switch C930-9, circuit Switch in this section. TEST the system
CPW25 (YE/BU), harness side. for normal operation.
No
REPAIR the open circuit CPW25
(YE/BU) or CPW26 (BU/BN) for an
operation.
Measure the resistance between power vent window

open relay pin 2, circuit CPW26 (BU/BN), harness
side and power vent window switch C930-4, circuit
CPW26 (BU/BN), harness side.
WINDOW
H5 CHECK THE POWER VENT WINDOW OPEN

AND CLOSE RELAY
Yes
Carry out the relay component test on the power vent GO to H6 .
window open and close relays.
No
Refer to Wiring Diagrams Cell 149 for component INSTALL a new relay. TEST the system
testing. for normal operation.
Did the power vent window open and close relay
pass the component test?
H6 CHECK FOR POWER TO THE VENT WINDOW
OPEN AND CLOSE RELAYS
Yes
Ignition ON. GO to H7 .
Measure the voltage between quarter window open
relay, harness side and ground. No
Pin 1, circuit CBP41 (BU) VERIFY Smart Junction Box (SJB) fuse
Pin 5, circuit CBP41 (BU) 41 (15A) is OK. If OK, REPAIR circuit
Measure the voltage between quarter window close CBP41 (BU) for an open. TEST the
relay, harness side and ground. system for normal operation.
Pin 2, circuit CBP41 (BU)
Pin 5, circuit CBP41 (BU) If not OK, REFER to the Wiring
Diagrams manual to identify the possible
causes of the circuit short. REPAIR the
circuit. TEST the system for normal
operation.

H7 CHECK CIRCUIT GD151 (BK/GN) FOR AN OPEN
Yes
Ignition OFF. GO to H8 .
Measure the resistance between quarter window open
relay and close relay, harness side and ground. No
Pin 4, circuit GD151 (BK/GN) REPAIR circuit GD151 (BK/GN) for an
operation.
WINDOW

H8 CHECK THE MOTOR CIRCUITS
Yes
Ignition OFF. INSTALL a new power vent window
Disconnect: Power Vent Window Motor C4047 (LH) regulator motor. REFER to Window
or C4090 (RH). Regulator Motor - Rear Quarter in this
Measure the resistance between power vent window section. TEST the system for normal
open relay pin 3, circuit CPW27 (GN), harness side operation.
and inoperative power vent window motor:
(RH) C4090-1, circuit CPW27 (GN). No
(LH) C4047-2, circuit CPW27 (GN). REPAIR circuit(s). TEST the system for
normal operation.
Measure the resistance between power vent window

close relay pin 3, circuit CPW28 (WH/BN), harness
side and power vent window motor:
(RH) C4090-2, circuit CPW28 (WH/BN).
(LH) C4047-1, circuit CPW28 (WH/BN).
WINDOW
Pinpoint Test I: The Defrost System is Inoperative
Normal Operation
With the engine running, the HVAC module activates the rear window defrost relay by grounding the relay
coil through circuit CH122 (WH/OG). When the defrost relay is activated, power is supplied from the relay to
the rear window defrost grid through circuit CRD06 (BN/YE). Ground is supplied to the rear window defrost
grid through circuit GD150 (BK/WH).

Fuse(s)
HVAC module
Open or short in rear window defrost grid
PINPOINT TEST I: THE DEFROST SYSTEM IS INOPERATIVE

I1 CHECK THE REAR WINDOW DEFROST GRID
VOLTAGE
Yes
Disconnect: Rear Window Defrost Grid Power C402A. GO to I2 .
Start the engine.
Activate the rear defrost switch and measure the voltage No
between rear window defrost grid power C402A, circuit GO to I3 .
CRD06 (BN/YE) and ground.


I2 CHECK THE REAR WINDOW DEFROST GRID
GROUND
Yes
Ignition OFF. CARRY OUT the Grid Wire Test
Disconnect: Rear Window Defrost Grid Ground C402B. in this section. REPAIR the rear
Measure the resistance between rear window defrost grid window defrost grid or INSTALL
ground C402B, circuit GD150 (BK/WH) and ground. a new liftgate glass. REFER to
Window Grid Wire Repair in this
normal operation.
No

I3 CHECK THE POWER TO THE RELAY
Yes
Disconnect: Rear Window Defrost Relay.
Ignition ON. No
Measure the voltage between rear window defrost relay VERIFY Battery Junction Box
socket pin 1, circuit CBB52 (GN/WH), harness side and pin (BJB) fuse 51 (40A) and fuse 52
3, circuit SBB51 (BU/RD), harness side and ground. (10A) are OK. If OK, REPAIR the
circuit. TEST the system for
normal operation.
If not OK, REFER to the Wiring


I4 CHECK THE HVAC MODULE OUTPUT
PINPOINT TEST I: THE DEFROST SYSTEM IS INOPERATIVE 604

NOTICE: The following step uses a test light to simulate Yes

normal circuit loads. Use only the test light GO to I5 .
recommended in the Special Tools table at the beginning
of this section. To avoid connector terminal damage, use No
the Flex Probe Kit for the test light probe connection to GO to I6 .
the vehicle. Do not use the test light probe directly on
any connector.
Start the engine.

Activate the rear defrost switch.
Connect a 12-volt incandescent test light between rear
window defrost relay socket pin 2, circuit CH122 (WH/OG)
and rear window defrost relay socket pin 1, circuit CBB52
(GN/WH).
Does the test light illuminate?

I5 CHECK THE REAR WINDOW DEFROST RELAY
Yes
Ignition OFF. REPAIR open in circuit CRD06
Carry out the rear window defrost relay component test. (BN/YE). TEST the system for
normal operation.
Refer to Wiring Diagrams Cell 149 for component testing.
Did the rear window defrost relay pass the component No
test? INSTALL a new rear window
defrost relay. TEST the system for
normal operation.
I6 CHECK CIRCUIT CH122 (WH/OG) FOR AN OPEN
Yes
Disconnect: HVAC Module - EATC C228B or HVAC
Module - EMTC C2357B. No
Measure the resistance between rear window defrost relay REPAIR the circuit. TEST the
socket pin 2, circuit CH122 (WH/OG), harness side and system for normal operation.
C228B-23 (HVAC module - Electronic Automatic
Temperature C (EATC)) or C2357B-23 (HVAC module -
Electronic Manual Temperature Control (EMTC)) circuit
CH122 (WH/OG), harness side.
PINPOINT TEST I: THE DEFROST SYSTEM IS INOPERATIVE 605


I7 CHECK FOR CORRECT HVAC MODULE
Yes
Disconnect all HVAC module connectors. INSTALL a new HVAC module.
Check for: TEST the system for normal
corrosion. operation.
pushed-out pins.
Connect all HVAC module connectors and make sure they No
seat correctly. The system is operating correctly
Operate the system and verify the concern is still present. at this time. Concern may have
Is the concern still present? been caused by a loose or corroded
connector. TEST the system for
normal operation.
Pinpoint Test J: The Defrost System Will Not Shut Off Automatically
Normal Operation
With the engine running, the HVAC module activates the rear window defrost relay by providing grounding
the relay coil through circuit CH122 (WH/OG). When the defrost relay is activated, power is supplied from
the rear window defrost relay through circuit CRD06 (BN/YE) to the rear window defrost grid. Ground is
supplied to the rear window defrost grid through circuit GD150 (BK/WH).

HVAC module
PINPOINT TEST J: THE DEFROST SYSTEM WILL NOT SHUT OFF AUTOMATICALLY


J1 CHECK CIRCUIT CRD06 (BN/YE) FOR A SHORT TO
VOLTAGE
Yes
Disconnect: Rear Window Defrost Relay. REPAIR circuit CRD06
Ignition ON. (BN/YE) for a short to
Is the rear window defrost ON? voltage. TEST the system for
normal operation.
No
GO to J2 .
J2 CHECK THE HVAC MODULE OUTPUT
Yes
NOTICE: The following step uses a test light to simulate GO to J3 .
normal circuit loads. Use only the test light recommended in
the Special Tools table at the beginning of this section. To No
avoid connector terminal damage, use the Flex Probe Kit for INSTALL a new rear window
the test light probe connection to the vehicle. Do not use the defrost relay. TEST the
test light probe directly on any connector. system for normal operation.
Start the engine.

Connect a 12-volt incandescent test light between rear window
defrost relay socket pin 2, circuit CH122 (WH/OG) and rear
window defrost relay socket pin 1, circuit CBB52 (GN/WH).
Does the test light illuminate?

J3 CHECK CIRCUIT CH122 (WH/OG) FOR A SHORT TO
GROUND
Yes
Ignition OFF. REPAIR short to ground in
Disconnect: HVAC Module - EATC C228B or HVAC Module - circuit CH122 (WH/OG).
EMTC C2357B. TEST the system for normal
Measure the resistance between rear window defrost relay socket operation.
pin 2, circuit CH122 (WH/OG), harness side and ground.
No
GO to J4 .
PINPOINT TEST J: THE DEFROST SYSTEM WILL NOT SHUT OFF AUTOMATICALLY 607

J4 CHECK FOR CORRECT HVAC MODULE OPERATION
Yes
Disconnect all HVAC module connectors. INSTALL a nVAC module.
pushed-out pins.
Connect all HVAC module connectors and make sure they seat No
operation.
Pinpoint Test K: The Delayed Accessory is Inoperative
Normal Operation
The accessory delay relay receives power at all times through circuit SDC04 (RD). When the ignition key is
turned ON, the Smart Junction Box (SJB) activates the accessory delay relay, which provides power to the LH
front window switch (Expedition) through circuit CBP47 (GN/BU). For Navigator, delayed accessory power
is provided to the LF and RF power window motors, RH front window switch and front window circuits in
the LH front window switch through circuit CBP41 (BU). The rear window circuits are powered by circuit
CBP47 (GN/BU). The delayed accessory feature remains active for 10 minutes after the ignition key is turned
OFF or until either front door is opened.
DTC 1302 (Accessory Delay Relay Coil Circuit Failure) - Sets when an open or short to ground is
detected on the relay control circuit.
DTC 1304 (Accessory Delay Relay Coil Circuit Short To Battery) - Sets when a short to voltage is

Circuit breaker


SJB
PINPOINT TEST K: THE DELAYED ACCESSORY IS INOPERATIVE

K1 CHECK THE DOOR AJAR SWITCH
OPERATION
Yes
Open and close the front doors. Verify the interior VERIFY SJB circuit breaker 47 (30A) is
lights turn on when the doors are open, and off when OK. If OK, GO to K2 .
the doors are closed.
Do the interior lights operate normally? No
REFER to Section 417-02 to diagnose the
interior lighting and door ajar switches.
K2 CHECK THE ACCESSORY DELAY RELAY
Yes
Disconnect: Accessory Delay Relay. GO to K3 .
Carry out the accessory delay relay component test.
No
Refer to Wiring Diagrams Cell 149 for component INSTALL a new accessory delay relay.
testing. TEST the system for normal operation.
Did the accessory delay relay pass the component
test?
K3 CHECK THE POWER TO THE ACCESSORY
DELAY RELAY
Yes
Ignition ON. GO to K5 .
Measure the voltage between accessory delay relay
socket pin 86, circuit SDC04 (RD), harness side and No
ground; and between accessory delay relay socket GO to K4 .
pin 30, circuit SDC04 (RD), harness side and
ground.
PINPOINT TEST K: THE DELAYED ACCESSORY IS INOPERATIVE 609


K4 CHECK CIRCUIT SDC04 (RD) FOR AN OPEN
Yes
Ignition OFF. GO to K5 .
power. No
Disconnect: SJB C2280C. REPAIR circuit SDC04 (RD) for an open.
Measure the voltage between SJB C2280C-1, circuit TEST the system for normal operation.
SDC04 (RD), harness side and ground.

K5 CHECK FOR CORRECT SJB OPERATION
Yes
Disconnect all SJB connectors. INSTALL a new SJB . TEST the system
Check for: for normal operation.
corrosion.
pushed-out pins. No
Connect all SJB connectors and make sure they seat The system is operating correctly at this
correctly. time. Concern may have been caused by a
Operate the system and verify the concern is still loose or corroded connector. CLEAR the
present. DTCs. REPEAT the self-test. TEST the
Is the concern still present? system for normal operation.
Pinpoint Test L: The Delayed Accessory Does Not Turn Off
PINPOINT TEST K: THE DELAYED ACCESSORY IS INOPERATIVE 610

Normal Operation
The accessory delay relay receives power at all times through circuit SDC04 (RD). When the ignition key is
turned ON, the Smart Junction Box (SJB) activates the accessory delay relay, which provides power to the LH
front window switch (Expedition) through circuit CBP47 (GN/BU). For Navigator, delayed accessory power
is provided to the LF and RF power window motors, RH front window switch and front window circuits in
the LH front window switch through circuit CBP41 (BU). The rear window circuits are powered by circuit
CBP47 (GN/BU). The delayed accessory feature remains active for 10 minutes after the ignition key is turned
OFF or until either front door is opened.
DTC 1302 (Accessory Delay Relay Coil Circuit Failure) - Sets when an open or short to ground is

SJB
PINPOINT TEST L: THE DELAYED ACCESSORY DOES NOT TURN OFF

L1 CHECK FOR STUCK/STICKING ACCESSORY
DELAY RELAY
Yes
Disconnect: Accessory Delay Relay. GO to L3 .
Are the power windows still operative?
No
GO to L2 .
L2 CHECK THE ACCESSORY DELAY RELAY
Yes
Carry out the accessory delay relay component test. GO to L4 .

testing. INSTALL a new accessory delay relay.
Did the accessory delay relay pass the component TEST the system for normal operation.
test?
L3 CHECK CIRCUIT CBP47 (GN/BU) FOR A SHORT
TO VOLTAGE
Yes
Ignition OFF. REPAIR circuit CBP47 (GN/BU) or
Disconnect: SJB C2280D. CBP41 (BU) for a short to voltage. TEST
Ignition ON. the system for normal operation.
Measure the voltage between SJB C2280D-32,
circuit CBP47 (GN/BU), harness side and ground; No
and for Navigator, also measure the voltage between GO to L4 .
SJB C2280D-16, circuit CBP41 (BU), harness side
and ground.


L4 CHECK FOR CORRECT SJB OPERATION
Yes
Disconnect all SJB connectors. INSTALL a new SJB . TEST the system
Check for: for normal operation.
corrosion.
pushed-out pins. No
Connect all SJB connectors and make sure they seat The system is operating correctly at this
correctly. time. Concern may have been caused by a
Operate the system and verify the concern is still loose or corroded connector. CLEAR the
present. DTCs. REPEAT the self-test. TEST the
Is the concern still present? system for normal operation.
Pinpoint Test M: A Single Power Window Does Not Operate Correctly - Slow Upward/Downward
Window Travel
Normal Operation
Under normal operation, it should not take longer than 6 seconds for the window to travel to the fully OPEN
or CLOSED position.

Dirt or contaminants in glass run
Glass runs not fully seated
Exterior beltline moulding
Window regulator and motor assembly
PINPOINT TEST M: A SINGLE POWER WINDOW DOES NOT OPERATE CORRECTLY - SLOW
UPWARD/DOWNWARD WINDOW TRAVEL

M1 CHECK THE POWER WINDOW
OPERATION
Yes
Start the engine. GO to M2 .
Monitor the amount of time it takes for the
suspect window to operate to the fully OPEN No
and CLOSED positions. The system is functioning correctly at this time.
Does it take more than 6 seconds for the
window to travel to the fully OPEN or
CLOSED positions?
PINPOINT TEST L: THE DELAYED ACCESSORY DOES NOT TURN OFF 612
M2 CHECK THE GLASS RUNS AND

EXTERIOR BELTLINE MOULDING
CONDITION
Yes
Visually inspect the exterior beltline moulding
and glass runs for correct installation or any No
damage. REINSTALL or INSTALL a new exterior
Is the exterior beltline moulding and glass beltline moulding and/or glass run. TEST the
runs OK? system for normal operation. For information
regarding the exterior beltline moulding, REFER
to Section 501-08 . For information regarding the
glass runs, REFER to Door Glass Top Run -
Front or Door Glass Top Run - Rear in this
section.
M3 LUBRICATE THE GLASS RUNS AND
BELTLINE MOULDING
Yes
Remove/clean the glass runs and beltline INSTALL a new window regulator and motor
mouldings using a clean cloth saturated with assembly. For information, REFER to Window
silicone spray. For LH front Regulator - Front Door or Window Regulator -
(Expedition/Navigator) or RH front Rear Door in this section. TEST the system for
(Navigator), de-initialize, then initialize the normal operation.
window motor. Refer to Window Motor
Initialization in this section. Test the system No
for normal operation. The system is functioning correctly at this time.
Component Test
Grid Wire Test
1. Using a bright lamp in the vehicle, inspect the wire grid from the exterior. A broken grid wire will
appear as a brown spot.
2. Run the engine at idle. Set the heated rear window switch to ON. The indicator light should come on.
3. Working in the vehicle with a voltmeter, contact the broad red-brown stripes of the rear glass window
positive lead to battery side and the negative lead to ground side. The meter should read 10-13 volts.
A lower voltage reading indicates a loose ground connection.
4. Contact a good ground point with the negative lead of the meter. The voltage reading should not
change.
5. With the negative lead of the meter grounded, touch each grid line of the heated rear window glass at
its midpoint with the positive lead. A reading of approximately 6 volts indicates the line is good. A
reading of 0 volt indicates the line is broken between the midpoint and the B+ side of the grid line. A
reading of 12 volts indicates the circuit is broken between the midpoint of the grid line and ground.
6. Pinpointing the exact position of the break can be accomplished (if the voltmeter reads 0 volt
when the midpoint of the grid line is touched with the positive lead of the voltmeter) by
moving the positive lead of the voltmeter toward the B+ side of the grid line and touching the
grid line until the voltmeter reads 12 volts. If the voltmeter reads 12 volts when the midpoint
of the grid line is touched with the positive lead of the voltmeter, simply move the positive
PINPOINT TEST M: A SINGLE POWER WINDOW DOES NOT OPERATE CORRECTLY - SLOWUPWARD
613
lead of the voltmeter toward the ground connection of the grid line and touch the grid line
until the voltmeter reads 0 volt.
PINPOINT TEST M: A SINGLE POWER WINDOW DOES NOT OPERATE CORRECTLY - SLOWUPWARD
614
Glass Reseal - Windshield
Material
Item Specification
Dow Urethane Adhesive -
BetasealTM Express
Sika Urethane Adhesive -
Sika Tack ASAP
Ultra-Clear Spray Glass Cleaner ESR-M14P5-A
ZC-23
1. Remove the cowl panel grille. For additional information, refer to Section 501-02 .
2. Remove the A-pillar trim panels. For additional information, refer to Section 501-05 .
3. If equipped, remove the overhead console. For additional information, refer to Section 501-12 .
4. If equipped, remove the rain sensor. For additional information, refer to Section 501-16 .
5. If equipped, remove the roof opening panel trim.
6. Remove the interior rear view mirror. For additional information, refer to Section 501-09 .
7. Remove the sun visors.
8. Partially lower the front portion of the headliner near the windshield upper opening and block with a
suitable material.
9. Clean the edge formed by the existing urethane adhesive and the glass on the inside at the top and
sides, and outside on the bottom of the windshield with glass cleaner.
10. Cut the urethane adhesive applicator tip to specification.
11. NOTE: Use either a high-ratio electric or battery-operated caulk gun that will apply the urethane
adhesive with less effort and a continuous bead.
Apply a bead of urethane adhesive to the cleaned area.
12. NOTE: Make sure that all gaps in the urethane adhesive are smoothed into one continuous bead.
Glass Reseal - Windshield 615

Backfill the urethane application and clean the excess.
13. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air or water
leaks.
After the urethane adhesive has cured, check the windshield seal for air or water leaks through the
urethane adhesive bead and add urethane adhesive as necessary.
14. Reposition the headliner.
15. Install the sun visors.
16. Install the interior rear view mirror. For additional information, refer to Section 501-09 .
17. If equipped, install the roof opening panel trim.
18. If equipped, install the rain sensor. For additional information, refer to Section 501-16 .
19. If equipped, install the overhead console. For additional information, refer to Section 501-12 .
20. Install the A-pillar trim panels. For additional information, refer to Section 501-05 .
21. Install the cowl panel grille. For additional information, refer to Section 501-02 .
22. Clean the interior and exterior of the windshield glass with glass cleaner.
Glass Reseal - Windshield 616

Window Motor Initialization
NOTE: Initialization is required to learn both the full UP and full DOWN positions and the profile of the
glass as it travels through the glass channel. Once initialized, obstacle detection is enabled. This procedure is
only required for Navigator (LF and RF) or Expedition (LF only) window motors.
NOTE: The window motor must be initialized whenever: the motor is removed from window regulator drum
housing, a new motor is installed, a new window regulator is installed, new window glass is installed, glass
top run removal or installation is carried out or when carrying out any operation in which grease or lubricants
are applied to the window system. All window components (window glass, window regulator, window motor
and glass top run) must be installed and tightened to specification before carrying out this procedure. Refer to
the De-Initialization Procedure in this section prior to performing the window motor initialization (unless a
new motor is being installed).
NOTE: A new (or de-initialized) LF/RF (Navigator) or LF (Expedition) window motor will not operate in
one-touch up mode until initialized. If a new LF/RF window motor has been installed, proceed to the Window
Motor Initialization procedure in this section.
NOTE: Excessive bounce-back (window reverses direction with no obstructions present) may indicate that a
de-initialization procedure may need to be performed.
De-Initialization Procedure
1. Start with the ignition key in the RUN position and open one front door.
2. NOTE: Steps 2 and 3 must be performed within 8 seconds.
Turn the ignition key from OFF to RUN 5 times.
3. Press the window control switch to the one-touch DOWN position (second detent) and release.
Window Motor Initialization
WARNING: Keep objects and body parts clear of the glass panel when carrying out the
initialization procedure. During the initialization procedure, the glass panel closes with high force and
cannot detect objects in its path. Failure to follow this instruction may result in serious personal injury.
4. Start with the ignition key in the OFF position and with the LF/RF door open.
5. Turn the ignition key to the ON position.
6. Activate and hold the window control switch in the one-touch DOWN position (second detent) until
the window glass stalls for 2 seconds at the bottom of its travel and release the switch.
7. NOTE: After performing this step, wait a minimum of 3 seconds before operating the window control
switch or ignition switch.
Activate and hold the window control switch (with no interruptions) in the one-touch UP position
(second detent) until the window glass stalls for 2 seconds into the glass top run and release the
switch.
Window Motor Initialization 617

8. Verify correct operation of the window by carrying out the one-touch up and one-touch down
features. If the window does not operate correctly, carefully repeat this procedure.
Window Motor Initialization 618

Window Grid Wire Repair
General Equipment
Polypropylene Film Fine Line Tape (Commercially

available)
Material
Item Specification
Lacquer Touch-Up Paint (match ESR-M2P100-C
color to exterior grid wire)
PM-19500-XXXX
Rear Window Defroster Repair -
PM-11 (US); CPM-11 (Canada)
ZC-23
NOTE: The grid line material is not embedded into the glass, but is baked to the glass surface and
consequently can be scraped off. An undamaged grid line will have small ridges that project above the surface
of the glass and can easily be felt when running a fingernail across them. Grid lines that have been "razor
bladed" will feel smooth when a fingernail is dragged across the affected area. Inoperative lines may appear to
the eye to be undamaged due to residue remaining on the glass and will require diagnosis with a voltmeter or
12V test lamp. For additional information, refer to Diagnosis and Testing in this section.
1. Bring the vehicle up to a room temperature of at least 16C (60F) or above.
2. NOTICE: Do not use scrapers, sharp instruments or abrasive window cleaners on the interior
surface of the rear window glass as this may cause damage to the grid lines.
Clean the entire grid line repair area with glass cleaner and 0000 steel wool to remove all dirt, wax,
grease, oil or other foreign material.
3. Mark the location of the grid break on the exterior of the rear window glass.
4. Using a polypropylene film fine line tape, mask the area directly above and below the grid break
extending the tape 26 mm (1.02 in) beyond the concern area in both directions. The break area should
be at the center of the mask.
Window Grid Wire Repair 619

5. NOTE: If the brown layer is not broken or missing, apply only the silver grid repair compound to the
break. If both the brown and silver layers of the grid are broken or missing, apply a coating of the
lacquer touch up paint across the break in the grid line prior to applying the rear window defroster
repair compound. Do not overlap the silver grid line with the paint. Several applications may be
necessary to achieve a color match.
NOTE: Allow at least 5 minutes of drying time between applications for the touch up paint or the
silver repair coating. Applying fewer coats or not allowing adequate drying time between coats will
produce repaired resistance that is greater than OEM resistance, resulting in poor defrost performance
and excessive localized heating.
Apply the repair coating to the grid break area in several smooth, continuous strokes. Extend the
silver repair coating at least 6.35 mm (0.25 in) on both sides of the break area.
Apply a minimum of 6 applications of the grid repair compound.
6. NOTE: The repair coating air-dries in approximately one minute and can be energized after 5
minutes. Optimum adhesion occurs after approximately 24 hours.
Allow the repair area to dry completely and remove the mask.
7. NOTICE: Be careful not to damage the grid line with the razor blade. If this occurs, additional
repair may be necessary.
Remove any excess repair compound above or below the grid line with a razor blade.
8. NOTE: The interior side of the grid lines are not painted, but due to the silver tarnishing will tend to
change the grid to a gold or brown color. The repair area will be bright silver and will also tarnish
over time to match the rest of the grid.
Test the system for normal operation.


Lead Terminal Repair
General Equipment
Terminal Kit - Back Glass 4F1Z-14421-AA
Material
Item Specification
ZC-23
1. Bring the vehicle up to room temperature of at least 16C (60F) or above.
2. NOTE: The new terminal will cover the original terminal location, but it must be placed so that the
terminal conductive areas will be placed on a good conductive base.
Clean the bus bar in the area to be repaired with steel wool (000 to 0000 grade), and then with glass
cleaner to remove all dirt, wax, grease, oil or other foreign material.
3. NOTICE: Do not use any type of flame torch or flame-heated soldering gun for this procedure.
Use of these tools provide inadequate heat generation at the tip and the exhaust heat can cause
damage to plastic trim parts in the area. Use only an electric soldering gun with 100 watts or
more of power. Before using the soldering gun, be sure to melt a small amount of rosin core
solder to the tip. The solder will assist in achieving better heat transfer from the soldering gun
tip to the new terminal.
NOTE: Depending on the original terminal location, and whether the terminal is covered by pillar
trim, will determine where to locate the new terminal. Some grid line bus bars may only allow the
placement of the terminal above or below the original tab location due to space limitations. For most
vehicle ications, the replacement tab location will cover the original tab location, but still allow the
replacement tab to attach to the bus bar on good conductive material.
Place the replacement terminal type A over the original tab location, making sure the conductive areas
of the terminal will be on a good conductive area. Do not place the terminal tab foot on the original
location, which does not have conductive material.
4. Hold the terminal in place with an item such as a regular lead pencil at a 90 degree angle from the
terminal. (Holding at other than a 90 degree angle may allow the terminal to slip when the solder
liquefies.)
Lead Terminal Repair 622

5. NOTE: The new terminal has pre-applied solder, flux and temperature-sensitive paint. The paint
provides a visual indication when the terminal has reached the correct temperature to melt solder on
the terminal. When the correct temperature is achieved, the temperature paint will liquefy and change
color.
Place the soldering gun tip on the top of the terminal, but not on the painted areas of the tab. Energize
the soldering gun and watch for the painted area of the terminal to liquefy and change color. The paint
should liquefy in approximately 25-45 seconds after heating. As soon as the paint color completely
changes on either side of the terminal, de-energize the soldering gun and continue to hold the terminal
in place with the soldering gun and pencil for an additional 30 seconds.
6. Remove the soldering gun and pencil from the terminal. The terminal should be allowed to cool for
another 2 minutes before the wiring lead is attached to the terminal.
7. Attach the electrical lead connection to this terminal, turn on the heated rear window and verify the
operation.
Lead Terminal Repair 623

Windshield Glass
Special Tool(s)
Deluxe Windshield Removal Tool

The Pumper
Material
Item Specification
Dow Urethane Adhesive -
BetasealTM Express
Dow Urethane One Step Glass Primer -
BetaprimeTM 5500 / 5500A /
5500SA
Sika Urethane Adhesive -
Sika Tack ASAP
Sika Urethane Metal and Glass -
Primer
Sika 206 G+P
ZC-23

1 51692 Windshield side moulding (2 required)
2 03110 Windshield top weatherstrip
3 03100 Windshield glass
Removal
Windshield Glass 624

NOTE: If the windshield glass is being removed to repair a dust/water leak, remove and reinstall the existing
windshield glass.
1. Remove the cowl panel grille. For additional information, refer to Section 501-02 .
2. Remove the A-pillar trim panels. For additional information, refer to Section 501-05 .
3. If equipped, remove the overhead console. For additional information, refer to Section 501-12 .
4. If equipped, remove the rain sensor. For additional information, refer to Section 501-16 .
5. Remove the interior rear view mirror. For additional information, refer to Section 501-09 .
6. Remove the sun visors.
7. Lower the front portion of the headliner.
8. Remove the windshield side mouldings.

Pull out starting at the top corner.
9. Remove the upper windshield weatherstrip.

Pull out starting at the corner.
10. Mark the outside of the windshield glass with a wax pencil to avoid damaging the glass stops when
cutting the urethane adhesive.
11. Before cutting the urethane adhesive, remove dirt and other foreign material from the windshield
pinch weld area.
Use a clean shop towel or oil-free compressed air.
12. NOTE: Refer to manufacturer's instructions before using the Deluxe Windshield Removal Tool.
Lubricate the urethane adhesive with water to aid the Deluxe Windshield Removal Tool when cutting
the urethane adhesive.
13. WARNING: Always wear eye protection when servicing a vehicle. Failure to follow this
WARNING: Wear protective gloves when handling components or parts that have pointed

or sharp edges. Failure to follow this instruction may result in serious personal injury.
NOTICE: To avoid rust formation, use extreme care not to scratch the paint or primer, or
otherwise damage the pinch weld during glass removal.
NOTE: Insert the blade into the Deluxe Windshield Removal Tool so that the flat side is against the
glass. This will leave the entire urethane adhesive bead on the pinch weld and allow a dry fit of the
replacement windshield glass.
NOTE: Support the windshield glass as necessary to prevent the glass from dropping while cutting
the urethane adhesive.
Insert the Deluxe Windshield Removal Tool at the upper center of the windshield glass and work
toward the bottom corners.
14. Using The Pumper, distance the windshield from the body.
15. Insert the Deluxe Windshield Removal Tool into the bottom of the urethane adhesive and cut from
corner to corner.
16. NOTE: Removing the windshield glass requires more than one technician.
Carefully remove the windshield glass from the vehicle and place on a stable work surface.
Installation
1. Dry-fit the windshield glass on the existing urethane adhesive bead on the pinch weld.
Position the windshield glass on the pinch weld.
Center the windshield glass in the opening.
Adjust the windshield glass stop blocks (if equipped) as needed for best fit.
Make alignment marks with tape or non-staining grease pencil (preferably at the windshield
glass stop blocks) on the windshield glass and the body.
2. After the dry-fit alignment, remove the windshield glass and place on a stable work surface with the
interior side of the glass facing upward.
3. WARNING: Repair any corrosion found on the pinch weld. The pinch weld is a structural
component of the vehicle. Corrosion left unrepaired may reduce the structural integrity of the
vehicle. Failure to follow this instruction may result in serious injury to vehicle occupant(s).

NOTE: Avoid scratching the pinch weld. Repair all minor scratches or exposed metal on the pinch
weld following manufacturer's instructions. Use the same brand pinch weld primer, glass primer and
urethane adhesive.
Using an appropriate tool, trim the urethane adhesive leaving a 1-2 mm (0.04-0.8 in) base or original
equipment urethane adhesive on the pinch weld.
4. Using a clean shop towel, brush or oil-free compressed air, clean the pinch weld area around the
existing urethane adhesive. Remove any foreign material or water that may have entered during
windshield removal.
5. If reinstalling the same windshield glass, remove any remaining urethane adhesive from the glass
leaving a thin layer to bond with the new urethane adhesive bead.
6. Clean the inside of the new windshield glass with glass cleaner.
Make sure to thoroughly clean the surface of the blackened border area where the urethane
adhesive will be applied.
7. NOTE: Be sure to use the same brand and cure-rate products for the urethane adhesive and glass
primer. Do not mix different brands of urethane adhesive and glass primer. Refer to the Material
Chart in this procedure.
If installing a new windshield glass, apply glass primer according to manufacturer's instructions.
Allow at least 6 minutes to dry.
8. Install the upper windshield weatherstrip.
9. Cut the urethane adhesive applicator tip to specification.
10. NOTE: The windshield glass must be positioned within 10 minutes of applying the urethane
adhesive.

Apply a uniform bead of urethane adhesive on top of the existing trimmed urethane adhesive bead on
the pinch weld just outside the foam butyl dam.
Make sure there are no gaps in the urethane adhesive bead.
11. WARNING: Do not drive vehicle until the urethane adhesive seal has cured. Follow
urethane adhesive manufacturer's curing directions. Inadequate or incorrect curing of the
urethane adhesive seal will adversely affect glass retention. Failure to follow these instructions
may result in serious injury to vehicle occupant(s).
NOTICE: Before positioning the windshield glass, open vehicle windows to prevent the air
pressure of closing doors from affecting the urethane adhesive bond.
Using the alignment marks made previously, position the windshield glass on the pinch weld.
12. NOTE: The urethane adhesive must cure for a minimum of one hour before testing for air or water
leaks.
After the urethane adhesive has cured, check the windshield glass seal for air or water leaks through
the urethane adhesive bead and add urethane adhesive as necessary.
13. NOTE: Be sure the moldings seat completely.
Install the windshield side mouldings.
14. Install the headliner.
15. Install the interior rear view mirror. For additional information, refer to Section 501-09 .
16. If equipped, install the rain sensor. For additional information, refer to Section 501-16 .
17. Install the overhead console. For additional information, refer to Section 501-12 .

18. Install the A-pillar trim panels. For additional information, refer to Section 501-05 .
19. Install the sun visors.
20. Install the cowl panel grille. For additional information, refer to Section 501-02 .
21. Run the blower motor on defrost HIGH to check for glass that may have fallen into the defroster
vents.

Window Control Switch
NOTE: LF shown, all others similar.
1. Remove the door trim panel. For additional information, refer to Section 501-05 .
2. NOTE: There are 2 tabs on the opposite side not shown in the illustration.
Unlock the 4 tabs and remove the window control switch from the door trim panel.
3. To install, reverse removal procedure.
Window Control Switch 630

Glass, Frames and Mechanisms - Exploded View, Front Door
Part
1 - Front door weathershield
2 21434 Inside glass weatherstrip
3 W710330 Front door top run channel bolt
4 - Window glass clamp bolts (part of glass regulator
assembly) (2 required)
5 21410 Front door glass
6 21596 Front door top run
7 - Front door glass regulator motor bolt (3 required)
8 23394 Front door glass regulator motor
9 W710330 Front door glass regulator frame bolt (8 required)
10 23208 Front door glass regulator assembly
11 21452 Outer glass weatherstrip
Glass, Frames and Mechanisms - Exploded View, Front Door 631

Glass, Frames and Mechanisms - Exploded View, Front Door 632

Door Glass Top Run - Front
NOTE: The power window regulator motor must be initialized whenever the LF/RF (Navigator) or LF
(Expedition) motor is removed from the vehicle. For additional information, refer to Window Motor
1. Remove the front door window glass. For additional information, refer to Window Glass - Front Door
in this section.
2. Remove the inside glass weatherstrip.
3. Remove the front door glass channel bolt and front door glass top run.

The power window regulator motor must be initialized whenever the LF/RF (Navigator) or
LF (Expedition) motor is removed from the vehicle. For additional information, refer to
Door Glass Top Run - Front 633

Door Glass Top Run - Front 634

Window Glass - Front Door
Removal
3. Remove the screws and the front door speaker.

4. Remove the front door weathershield.
5. Re-connect the electrical connectors to the window control switch.
6. Lower the window glass to access the 2 window glass clamp bolts.
Window Glass - Front Door 635

8. Remove the front door glass channel bolt and position aside the channel.
9. Loosen the window glass clamp bolts and remove the front door window glass.
Installation
1. Install the front window glass but do not tighten the window glass clamp bolts.
2. Position the front door glass channel and tighten the bolt to 11 Nm (97 lb-in).
3. Install the inside glass weatherstrip.
4. Raise the window glass until it stalls in the UP position. Tighten the window glass clamp bolts to 11
Nm (97 lb-in).
5. Disconnect the window control switch electrical connectors and reinstall the switch into the door trim
panel.

6. Install the front door weathershield.
7. Install the front door speaker.

Connect the electrical connector and install the screws.
8. Install the front door trim panel. For additional information, refer to Section 501-05 .
LF (Expedition) motor is removed from the vehicle. For additional information, refer to

Window Regulator - Front Door
3. Remove the screws and the front door speaker.

4. Remove the front door weathershield.
5. Re-connect the electrical connectors to the window control switch.
6. Lower the window glass to access the 2 window glass clamp bolts.
7. Loosen the window glass clamp bolts.

To install, raise the window glass until it stalls in the UP position. Tighten the window glass
clamp bolts to 11 Nm (97 lb-in).
Window Regulator - Front Door 638

8. NOTE: Secure the front window glass in the full UP position.
Secure the front window glass with tape to the front door frame.
9. Position the interior door handle aside.

1. Remove the cable conduit fitting from the carrier assembly.
2. Lift upward on the interior door handle retaining bracket and pivot the interior door handle
out of the bracket.
3. Remove the cable from the door handle.
10. Release the crash sensor harness pin-type retainers.
11. Position the front door window regulator harness aside.

2. Release the pin-type retainers.
12. Remove the front window regulator.

1. Loosen the 2 hanger bolts.
2. Remove the front window regulator bolts and front top run channel bolt.

LF (Expedition) window regulator is removed from the vehicle. For additional information,
refer to Window Motor Initialization in this section.

Window Regulator Motor - Front Door
2. Position the front door weathershield aside.
3. NOTE: Use a flat-blade screwdriver between the window regulator motor and window regulator
assembly to hold the window regulator assembly drum in place.
Remove the bolts and the front door window regulator motor.

2. Remove the bolts.

Cycle the window glass to make sure the gears engage.
LF (Expedition) window regulator is removed from the vehicle. For additional information,
refer to Window Motor Initialization in this section.
Window Regulator Motor - Front Door 641

Window Regulator Motor - Front Door 642

Glass, Frames and Mechanisms - Exploded View, Rear Door

1 - Rear door weathershield
2 25860 Inside glass weatherstrip
3 W710330 Rear door top run channel bolts (2
required)
4 - Window glass clamp bolts (part of glass
regulator assembly)
5 25712 RH/ 25713 LH Rear door glass
6 25766 RH/ 25767 LH Rear door top run
7 - Rear door glass regulator motor bolt (3
required)
8 23394 Rear door glass regulator motor
9 W710330 Rear door glass regulator frame bolt (8
required)
10 27008 Rear door glass regulator assembly
11 25596 Outer glass weatherstrip
12 W504041 Rear door vent glass frame screw
13 25828 Rear door vent glass assembly
Glass, Frames and Mechanisms - Exploded View, Rear Door 643

Glass, Frames and Mechanisms - Exploded View, Rear Door 644

Window Glass - Fixed, Rear Door
1. Remove the rear door window glass. For additional information, refer to Window Glass - Rear Door
in this section.
2. Remove the rear door exterior glass moulding. For additional information, refer to Section 501-08 .
3. Remove the rear door glass top run. For additional information, refer to Door Glass Top Run - Rear in
this section.
4. Remove the rear door stationary glass screw.
5. Remove the stationary rear door glass.
Window Glass - Fixed, Rear Door 645

Window Glass - Fixed, Rear Door 646

Door Glass Top Run - Rear
1. Remove the rear door window glass. For additional information, refer to Window Glass - Rear Door
in this section.
2. Remove the rear door glass channel bolt.

3. Remove the rear door glass top run.
Door Glass Top Run - Rear 647

Window Glass - Rear Door
1. Remove the rear door trim panel. For additional information, refer to Section 501-05 .
NOTE: LF shown, LR and RR are similar.
3. Position aside the rear door weathershield.
4. Connect the window control switch.
5. Raise or lower the window glass as necessary to access the window glass clamp bolts.
7. Remove the rear door glass channel bolt.

Window Glass - Rear Door 648

8. Loosen the window glass clamp bolts.

9. Tape the window in position, then lower the window regulator downward.
To install, raise the window regulator approximately 2.54 cm (1.0 in) from the full UP
position. Then, while manually pushing the glass into the rear channel, raise the window
regulator to the full UP position.
10. Lift the window glass out of the door.
Window Glass - Rear Door 649

Window Regulator - Rear Door
NOTE: LF shown, LR and RR are similar.
3. Remove the rear door speaker.

1. Remove the screws.
3. Remove the speaker.
4. Remove the rear door weathershield.
5. Connect the window control switch.
6. Lower the window glass to access the window glass clamp bolts.
7. Disconnect the window control switch.
8. Loosen the window glass clamp bolts and remove the rear door window glass.
Window Regulator - Rear Door 650

9. NOTE: Secure the rear window glass in the full UP position.
Secure the rear window glass with tape to the rear door frame.
10. Disconnect the rear door window regulator electrical connectors.
11. Position the interior door handle aside.

Lift upward on the interior door handle retaining bracket and pivot the interior door handle
out of the bracket.
12. Remove the rear door window regulator assembly.

Remove the bolts.


Window Regulator Motor - Rear Door
2. Position the rear door weathershield aside.
3. NOTE: Use a flat-blade screwdriver between the window regulator motor and the window regulator
assembly to hold the window regulator assembly drum in place.
Remove the rear door window regulator motor.


Cycle the door glass to make sure of gear engagement.
&nbspP>
Window Regulator Motor - Rear Door 653

Window Regulator Motor - Rear Door 654

Window Glass - Rear Quarter
Material
Item Specification
Foam Core Butyl WSB-M3G143-B1
E69Z-19562-A
Part
1 - Rear quarter window regulator motor bolt (3 required)
2 30306 Rear quarter window regulator assembly
3 N621901 Rear quarter window glass nuts (15 required)
4 - Rear quarter window hinge assembly (serviced with
quarter glass assembly)
5 29600 Rear quarter window glass assembly
Removal
All vehicles
2. Remove the front and rear coat hooks and lower the headliner over the rear quarter windo
Vehicles with power vent window
3. Remove the bolts and rear quarter window regulator motor.
Window Glass - Rear Quarter 655

4. Disconnect the rear quarter window regulator.
All vehicles
5. Disconnect the audio antenna.
6. If equipped, remove the air duct.

Remove the pin-type retainer.
7. NOTE: Have an assistant hold the rear quarter window glass.
Remove the rear quarter window glass.
1. Remove the nuts.

2. Remove the rear quarter window glass.
8. Remove the excess foam core butyl from the window opening.

Installation
All vehicles
1. Apply 8 mm (0.32 in) foam core butyl to the rear quarter window glass frame.
Start at the bottom middle and work around the frame.
2. Install the rear quarter window glass.

1. Position the rear quarter window glass.
2. Install the rear quarter window glass nuts.
Tighten to 2 Nm (18 lb-in).
3. If equipped, install the air duct.

Install the pin-type retainer.
4. Connect the audio antenna.
Vehicles with power vent windows
5. Install the rear quarter window regulator.

6. Install the bolts and rear quarter window regulator motor.

Connect the electrical connector.
All vehicles
7. Position the headliner and install the coat hooks.
8. Install the rear quarter trim panel. For additional information, refer to Section 501-05 .

Window Regulator Motor - Rear Quarter
Removal
1. Remove the D-pillar trim panel. For additional information, refer to Section 501-05 .
2. Disconnect the rear quarter window regulator motor.

Remove the retaining clip.
3. Remove the bolts and rear quarter window regulator motor.

Window Regulator Motor - Rear Quarter 659

Window Glass - Liftgate
Material
Item Specification
TA-26

1 42104 Liftgate glass assist cylinder (2 required)
2 W712536 Liftgate glass hinge-to-body fastener (2 required)
3 420A68 Liftgate glass hinge assembly (2 required)
4 422A12 Liftgate glass assembly
5 40610 Nylon spacer
6 - Liftgate glass-to-hinge bolt
Window glass assembly
1. Remove the rear window wiper motor. For additional information, refer to Section 501-16 .
2. Disconnect the rear window defrost electrical connectors.>
3. NOTICE: Do not extend the socket clips more than 2.0 mm (0.08 in) or failure of the socket can
occur.
Window Glass - Liftgate 660

NOTE: The liftgate glass must be supported when removing and installing the liftgate assist
cylinders.
Disconnect the 2 liftgate glass assist cylinders.
1. Insert a screwdriver blade under the socket clip and lift.

2. Gently pull the socket off the ball stud.
Window glass assembly or hinge assembly
4. Remove the liftgate glass hinge-to-body fasteners and remove the glass.
Window hinge assembly
5. Remove the liftgate glass to hinge fasteners and remove the glass.
Apply threadlock to the liftgate glass-to-hinge fasteners during installation.
Window glass assembly or window hinge assembly

Check the liftgate glass for high effort when closing. If high effort is present, adjust the striker
one-half turn outboard. If high effort is still present, adjust the striker an additional one-half
turn outboard. Do not exceed one full turn.


SECTION 501-12: Instrument Panel and Console 2011 Expedition, Navigator Workshop Manual

Assist handle bolts 6 - 53
Bracket-to-floor bolts 40 30 -
Bracket-to-instrument panel bolts 9 - 80
Front floor console bulkhead electrical 3 - 27
connector bolts
Front floor console front bolts 7 - 62
Front floor console rear bolts 7 - 62
Front floor console screws 7 - 62
Glove compartment screws 3 - 27
Hood release handle screw 3 - 27
Instrument cluster finish panel screws 3 - 27
Instrument panel bolts 28 21 - Instrument panel bulkhead electrical 5 - 44
connector bolt
Instrument panel cowl bolts 28 21 -
Instrument panel floor brace bolts 9 - 80
Parking brake release handle screw 3 - 27
Rear floor console front bolts 12 - 106
Steering column reinforcement panel bolts 9 - 80
Steering column shaft pinch bolt 30 22 -
Steering column opening trim panel screws 3 - 27


Instrument Panel - Exploded View
Expedition

1 W707628 Steering column opening trim panel
screws (3 required)
2 04459 Steering column opening trim panel
3 - Instrument panel lower cover
4 W710879 Steering column reinforcement panel
bolt (4 required)
5 017A28 Steering column reinforcement panel
6 14401 Instrument panel electrical wiring
harness connectors
7 N811040 Pin-type retainer (3 required)
8 - Valance panel
9 04480 Instrument panel side finish panel
10 W710879 Instrument panel floor brace bolts (6
required)
11 - Instrument panel floor brace RH
12 - Instrument panel floor brace LH
13 044E82 Instrument panel defroster grille
14 W706246 Instrument panel cowl bolt (5
required)
15 W706246nstrument panel bolt
(4 required)
Instrument Panel - Exploded View 665

16 04320 Instrument panel
Navigator

1 W707628 Steering column opening trim panel screws (3
required)
3 W710879 Steering column reinforcement panel bolt (4 required)
4 017A28 Steering column reinforcement panel
5 14401 Instrument panel electrical wiring harness connectors
6 04480 Instrument panel side finish panel
7 044E82 Instrument panel defroster grille
8 W706246 Instrument panel cowl bolt (5 required)
9 W706246 Instrument panel bolt (4 required)
10 04320 Instrument panel
Expedition 666
Navigator 667
Instrument Panel
All vehicles
1. If equipped with adjustable pedals, move the pedals to the full forward position.
2. If equipped, remove the front floor console. For additional information, refer to Console - Front,
Floor, Navigator or Console - Front, Floor, Expedition in this section.
3. Remove the steering wheel. For additional information, refer to Section 211-04 .
4. If equipped, remove the RH instrument panel insulator.

Disconnect the instrument panel insulator lamp.
5. Remove the LH and RH lower cowl trim panels.

Remove the scuff plate.
Remove the lower cowl trim panel.
6. Position the LH and RH door weatherstrip seals aside.
7. Remove the LH and Rpillar trim panels. For additional information, refer to Section 501-05 .
Navigator only
8. Remove the steering column opening trim panel.

Remove the screws.
Release the trim panel from the instrument panel.
Disconnect the electrical connector, if equipped.
Instrument Panel 668

9. Position the hood release and parking brake release handles aside.
Remove the screws.
Position the release handles aside.
Expedition only

Remove the screws.
Release the trim panel from the instrument panel.
11. Remove the hood release handle screw and position aside.
12. Remove the instrument panel lower cover.
13. Remove the screw from the parking brake handle and position aside.
All vehicles

14. NOTE: Navigator shown, Expedition similar.
Remove the bolts and the steering column reinforcement panel.
15. Loosen the bolt and disconnect the LH instrument panel bulkhead electrical connector.
16. Disconnect the LH electrical connectors.
17. Disconnect the park brake indicator connector.
18. Disconnect the cruise control deactivator and the brake on/off switch electrical connector.
19. Disconnect the electrical connector located above the Data Link Connector (DLC).

20. Disconnect the steering wheel position sensor electrical connector.
Column shift only
21. Disconnect the selector lever cable from the selector lever.
22. Remove the selector lever cable and position aside.

Remove the selector lever cable from the bracket.
Remove the selector lever cable and retainer from the steering column.
All vehicles
23. Remove the steering column shaft pinch bolt and disconnect the steering column shaft from the
steering column.
Discard the bolt.
To install, tighten the new bolt to 30 Nm (22 lb-ft).

Expedition only
24. Remove the floor console bracket bolts and position the floor console bracket aside.
25. If equipped, remove the 3 pin-type retainers and the valance panel.
All vehicles
26. If equipped, disconnect the Electronic Automatic Temperature Control (EATC) hose from the
evaporator case.
27. Disconnect the stability control sensor cluster electrical connector.

Disconnect the wiring harness from the console bracket.
28. Remove the satellite radio antenna from the wiring harness, if equipped.
29. NOTE: Navigator shown, Expedition similar.
Remove the RH instrument panel side finish panel.

30. Disconnect the RH instrument panel electrical connectors.

Remove the RH ground bolt.
Disconnect the in-line antenna connector.
31. Lower the glove compartment.
32. NOTE: There are 6 electrical connectors, 3 are shown.
33. Remove the 2 RH instrument panel floor brace bolts.

34. Remove the 2 LH instrument panel floor brace bolts.


Navigator only
35. Remove the bolts and position the floor console bracket aside.
Disconnect the electrical connector from the bracket.
Remove the bracket-to-instrument panel bolts.
Remove the bracket-to-floor bolts.
All vehicles
36. NOTE: RH brace shown, LH brace similar to Expedition.
Position the carpet aside, remove the bolts and the instrument panel floor braces.
Expedition only
37. Position the carpet aside, remove the bolts and the instrument panel floor brace.
All vehicles
38. Remove the instrument panel defroster grille.

39. Remove the instrument panel cowl bolts.

40. Remove the LH instrument panel bolts.

41. Remove the RH instrument panel bolts.

42. NOTE: This step requires an assistant.
NOTE: Two bullet connectors align the instrument panel to the bulkhead.
Remove the instrument panel.

Transfer parts as needed.
Make sure to align the trim panel retaining clips to the retaining clip holes in the instrument
panel and body.


Instrument Panel Finish Panel - Center, Navigator

1 W707628 Instrument panel center finish panel screws (2
required)
2 04302 Lower instrument panel center finish panel
3 W707628 Lower screw (2 required)
4 W704874 Upper screw (2 required)
5 - Upper instrument panel center finish panel
1. Apply the parking brake and move the selector lever to NEUTRAL.
2. Remove the selector lever trim ring.
3. Remove the front floor console finish panel.
4. Remove the lower instrument panel center finish panel.

Remove the instrument panel center finish panel screws.
Pull outward on the panel to disengage the clips.
Disconnect tctrical connectors.
Instrument Panel Finish Panel - Center, Navigator 677

5. Remove the 2 lower screws from the upper instrument panel center finish panel.
6. Remove the instrument panel defroster grille.
7. Remove the 2 upper screws from the upper instrument panel center finish panel.
8. Remove the upper instrument panel center finish panel.


panel.
Instrument Panel Finish Panel - Center, Navigator 678

Instrument Panel Finish Panel - Center, Expedition

1 - Lower instrument panel center finish panel
2 04302 Upper instrument panel center finish panel
1. Remove the lower instrument panel center finish panel.
2. Remove the upper instrument panel center finish panel.


panel.
Instrument Panel Finish Panel - Center, Expedition 679

Instrument Panel Finish Panel - Center, Expedition 680

Instrument Cluster Finish Panel - Expedition

required)
3 - Instrument cluster finish panel bridge
4 W707628 Instrument cluster finish panel screw (2 required)
5 04320 Instrument cluster finish panel
Column shift vehicles only
1. Place the selector lever to the 1 position.
All vehicles

Remove the 3 steering column opening trim panel screws.
Release the steering column opening trim panel from the instrument panel.
3. Tilt the steering wheel to the full down position.
Instrument Cluster Finish Panel - Expedition 681

4. Remove the instrument cluster fpanel bridge.

Pull upward and then left on the LH side of the finish panel bridge to release the retainer and
remove the finish panel bridge.
5. Remove the 2 instrument cluster finish panel screws.
6. Remove the instrument cluster finish panel.

Pull on the finish panel to release it from the retainers.

panel.
Instrument Cluster Finish Panel - Expedition 682

Instrument Cluster Finish Panel - Navigator

required)
3 W707628 Instrument cluster finish panel screws (2 required)
4 04320 Instrument cluster finish panel
1. Lower the steering column to the lowest position.
2. Remove the 3 screws and the lower steering column cover.

Disconnect the electrical connector for the brake pedal switch (if equipped).
3. Remove the 2 instrument cluster finish panel screws.
4. NOTE: There are 2 locking tabs on the outboard register that need to be depressed before the cluster
finish panel is removed.
NOTE: Cluster finish panel removed for clarity.
Depress the 2 locking tabs and remove the cluster finish panel.
Access the tabs from under the instrument panel.

Instrument Cluster Finish Panel - Navigator 683


panel.
Instrument Cluster Finish Panel - Navigator 684

Glove Compartment

1 W707628 Glove compartment screws (3 required)
2 06024 Glove compartment
1. Open the glove compartment.
2. NOTICE: Forcing the glove compartment past the stops will damage the dampener.
If equipped, disconnect the dampener.
3. Release the stops.
4. Remove the 3 glove compartment screws and the glove compartment.
Glove Compartment 685

Glove Compartment 686

Console - Front, Floor, Expedition

1 W706681 Front floor console rear bolts (2 required)
2 672A40 Front floor console bolt covers
3 W710806 Front floor console front bolts (2 required)
4 7E391 Selector lever trim ring
5 045G34B Front floor console utility tray mat
6 W707382 Front floor console utility tray screw
7 045A76 Front floor console upper finish panel
8 W710879 Front floor console front screws (2 required)
9 045A36 Front floor console
Removal
1. Apply the parking brake.
2. Position the selector lever in the NEUTRAL position.
3. Position the front seats forward.
4. Remove the 2 front floor console rear bolts.
Console - Front, Floor, Expedition 687

5. Position the front seats rearward.
6. Remove the 2 front floor console front bolts.

Remove the 2 front floor console bolt covers.
Remove the 2 front floor console bolts.
8. Remove the front floor console utility tray mat.
9. Remove the front floor console utility tray screw.
10. Remove the floor console upper finish panel.
11. Position the selector lever indicator bezel aside.

Release the 4 retainers and position aside.
12. Disconnect the selector lever cable from the selector lever and the floor console.

13. Remove the front floor console front screws.
14. Disconnect the front floor console electrical connectors.

1. Loosen the bulkhead electrical connector bolts.
2. Disconnect the bulkhead electrical connectors.
15. Remove the front floor console.
Installation
1. Install the front floor console.
2. Connect the front floor console electrical connectors.

Tighten the bulkhead electrical connector bolts to 3 Nm (27 lb-in).
3. Install the front floor console front screws.

4. Install the selector lever cable.
5. Install the selector lever indicator bezel.
6. Install the floor console upper finish panel.

Make sure to align the trim panel retaining clips to the retaining clip holes in the floor
console.
7. Install the front floor console utility tray screw.
8. Install the front floor console utility tray mat.
9. Install the selector lever trim ring.
10. Install the 2 front floor console front bolts.

11. Install the 2 front floor console front bolt covers.
13. Install the 2 front floor console rear bolts.

15. Position the selector lever in the PARK position.
16. Release the parking brake.

Console - Front, Floor, Navigator

1 W706681 Front floor console rear bolt (2
required)
2 - Selector lever trim ring
3 045A76 Front floor console finish panel
4 - Front cup holder insert
5 W710879 Front floor console front screws (2
required)
6 04608A Front floor console side cover RH
7 04608B Front floor console side cover LH
8 W710806 Front floor console front bolt (2
required)
9 06024 Front floor console storage
compartment door
10 - Rear cup holder
11 - Rear cup holder insert
12 - Rear cup holder trim ring
13 19N236 Front floor console front auxiliary
power point
14 W707658 Front floor console rear panel
screw (2 required)
15 045E24 Front floor console rear panel
Front floor console rear
19N236
auxiliary power point
Console - Front, Floor, Navigator 691

17 045A36 Front floor console

18 14B079 Bulkhead electrical connector
1. Place the selector lever in NEUTRAL and apply the parking brake.
3. Remove the 2 front floor console rear bolts.

5. NOTICE: Do not pull outward on the front of the front floor console side finish panel.
Otherwise, damage to the front floor console side finish panel will occur.
Remove the LH and RH front floor console side finish panels in the follow sequence.
1. Using a non-marring tool, pry the rear of the LH and RH front floor console side finish panels
outward to release the retaining clips.
2. Slide the LH and RH front floor console side finish panels rearward.
If equipped, disconnect the electrical connector.
6. Remove the LH and RH front floor console front bolts and the floor console.


Pull upward on the rear of the finish panel to release the retainers.
9. NOTE: RH retainers shown, LH similar.
Position the selector lever indicator bezel aside.
Release the 4 retainers.
10. Disconnect the selector lever cable from the selector lever and floor console.
11. Remove the front floor console front screws.

12. Disconnect the front floor console electrical connectors.

1. Loosen the bulkhead electrical connector bolts.
2. Disconnect the bulkhead electrical connectors.


console.

Console - Rear, Floor

1 04567 Rear floor console cup holder
2 W706599 Rear floor console front bolt (2 required)
3 W706599 Rear floor console rear bolts (2 required)
4 115A00 Rear floor console storage bin
5 13562 Rear floor console cup holder insert (2 required)
6 - Rear floor console cup holder trim ring
7 06024 Rear floor console storage compartment door
8 045A36 Rear floor console
1. Remove the 2 rear floor console front bolts.

Open the rear floor console storage bin.
Remove the rear floor console cup holder.
Remove the rear floor console front bolts.
2. Remove the 2 rear floor console rear bolts.
Console - Rear, Floor 695

Open the rear floor console storage compartment door.
Remove the rear floor console rear bolts.
Remove the rear floor console.

console.
Console - Rear, Floor 696

Console - Overhead
NOTE: Overhead console with roof opening panel shown, all others similar.

1 519A70 Overhead console
2 - Retaining clip
3 14335 Overhead console electrical connectors
1. Using a suitable trim removal tool, remove the overhead console by prying down on the overhead
console to release the 2 retaining clips.
2. Disconnect the electrical connector(s).

Make sure to align the overhead console retaining clips to the adjacent retaining clip holes.
Console - Overhead 697

Console - Overhead 698

Power Point
Special Tool(s)
Remover, Power Point Socket

Removal
NOTE: Power point cover may differ depending on location.
1. Open the power point cover.
2. Install the Power Point Socket Remover in one of the power point socket slots.
3. Position the Power Point Socket Remover so that it engages in the adjacent slot.
4. Using the Power Point Socket Remover, pull the power point socket out of the retainer.
Installation
1. Connect the electrical connector.
2. Slide the power point socket into the retainer.
Power Point 699

Power Point 700


SECTION 501-14: Handles, Locks, Latches and Entry Systems
Workshop Manual
Material

Capacity
Multi-Purpose Grease ESB-M1C93-B -
XG-4 and/or XL-5
Penetrating and Lock Lubricant - -
(US); Penetrating Fluid (Canada)
XL-1 (US); CXC-51-A (Canada)

Door latch bolts 12 - 106
Door striker bolts 25 18 -
Exterior door handle nuts 9 - 80
Hood latch bolts 35 26 -
Hood striker bolts 12 - 106
License plate housing nuts 5 - 44
Liftgate glass latch screws 8 - 71
Liftgate glass striker 6 - 53
5 - 44
Liftgate latch bolts 12 - 106
Liftgate release switch housing nuts (Navigator) 9 - 80
Liftgate striker bolts 25 18 -
Power Point 701

Power Point 702


Workshop Manual
Handles, Locks, Latches and Entry Systems
NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM).
Hood Latch
The hood latch consists of the following components:
Hood latch
Hood latch striker
Hood latch release handle and cable
Front Door
The front door consists of the following components:
Door ajar switch

Door lock cylinder (driver door only)
Exterior front door handle
Front door latch
Front door lock actuator
Interior door handle actuating cable
Interior front door handle
Keyless entry keypad (if equipped)
Rear Door
The rear door consists of the following components:
Door ajar switch

Exterior rear door handle
Interior door handle actuating cable
Interior rear door handle
Rear door latch
Rear door lock actuator
Liftgate
The liftgate consists of the following components:
Liftgate ajar switch (part of the liftgate latch)

Liftgate latch
Liftgate latch actuator (part of the liftgate latch)
Liftgate release switch (on the release handle for Expedition and on the rear license plate housing for
Navigator)
Liftgate Glass
The liftgate consists of the following components:
Liftgate glass ajar switch (part of the liftgate glass latch)
Handles, Locks, Latches and Entry Systems 703

Liftgate glass latch

Liftgate glass latch actuator (part of the liftgate glass latch)
Liftgate glass release switch (on the rear license plate housing)
Power Lock/Unlock
The power lock/unlock feature requests all of the vehicle doors locked or unlocked upon a customer request
from either interior door lock switch in the vehicle. The power door locking system functions independently
of ignition status or vehicle speed.
Autolock
The autolock feature locks all doors when all doors, including the liftgate, are closed, the brake pedal was
pressed with the ignition switch in the ON position, and a vehicle speed of 20 km/h (12 mph) or higher is
achieved. This feature relocks the doors (when any door is opened then closed) after the brake pedal is
pressed, once all doors are read as closed, and the vehicle speed exceeds 20 km/h (12 mph). The autolock
feature can be enabled/disabled. Refer to Autolock and Auto-Unlock Programming .
Auto-Unlock
NOTE: The doors does not auto-unlock if the vehicle has been electronically locked before the driver door is
opened.
The auto-unlock feature unlocks all the doors when the ignition is in the RUN position, all the doors are
closed, and the vehicle has been in motion at a speed greater than 20 km/h (12 mph), the vehicle then comes
to a stop and the ignition is switched to LOCK or ACC, and the driver's door is opened within 10 minutes of
the ignition being switched to LOCK or ACC. The auto-unlock feature can be enabled/disabled. Refer to
Autolock and Auto-Unlock Programming .
Smart Unlock
The smart unlock feature prevents the driver door from locking with the key in the ignition lock cylinder.
When the SJB receives a lock command from a door lock control switch with the key in the ignition lock
cylinder and the driver door open, the SJB commands all the doors to unlock.
The vehicle can still be locked by locking the doors with the push button rods, the door lock cylinder or an
RKE command from an Integrated Keyhead Transmitter (IKT) or the keyless entry keypad.
Remote Keyless Entry (RKE)
The RKE system uses an IKT . The IKT incorporates both the Passive Anti-Theft System (PATS) functions
and the RKE transmitter functions in a single device.
The RKE transmitter is programmed automatically during PATS programming. During PATS programming,
the Instrument Cluster (IC) obtains the Transmitter Identification Code (TIC) from the IKT and sends the TIC
data over the Medium Speed Controller Area Network (MS-CAN) to the SJB .
The SJB accepts programming of up to 4 IKTs . In addition to the IKTs , 4 conventional keyfobs can also be
programmed to the vehicle if requested by the customer. For information on programming the IKTs , refer to
Key Programming Using Two Programmed Keys or Integrated Keyhead Transmitter (IKT) Key Programming
Using Diagnostic Equipment in Section 419-01B . Refer to Remote Keyless Entry (RKE) Transmitter
Programming in this section for keyfob programming information.
Liftgate Glass 704

The RKE transmitter initiates the following electronic system functions:
Unlocks the driver door (with stepped unlock enabled)

Unlocks all doors
Locks all doors
Releases the liftgate window glass (vehicles without power liftgate)
Activates/deactivates the panic alarm
Issues a command to open/close the power liftgate (if equipped)
Issues a command to turn on the interior lamps (when unlocking) and off (when locking), provided
the defeat switch on the dimmer switch is not active
Provides a long flash of the turn signals when UNLOCK is pressed
Sounds the horn once when LOCK is pressed twice within 3 seconds, and the doors are closed
Sounds the horn twice when LOCK is pressed twice within 3 seconds, and any door is open
Flashes the turn signals once for each time LOCK is pressed, and the doors and liftgate are closed
If any door or liftgate is open, the turn signals does not flash when LOCK is pressed until all doors
and the liftgate are closed.
The RKE transmitter has a normal operating range of 10 m (33 ft).
Remote Keyless Entry (RKE) Lock/Unlock Control - Unlock
The RKE feature provides lock/unlock functions independently of ignition status, vehicle speed, or
transmission position. The RKE feature provides a 2-step process, if enabled, for unlocking the doors. Upon
receipt of the first request for unlocking the doors, the RKE feature requests the SJB to unlock the driver door
only and provides a long flash of the turn signals. If another unlock request is received within 3 seconds of the
first, the RKE feature requests that all doors be unlocked. This feature can be disabled so that all the doors
unlock on the first press of the UNLOCK button. Refer to Stepped Unlock Programming in this section for
programming information.
Remote Keyless Entry (RKE) Lock/Unlock Control - Lock
The RKE feature requests that all the doors be locked when the LOCK button is pressed any press of the lock
button with all doors closed, the RKE feature requests one flash of the turn signals. If any door is ajar, no flash
occurs, indicating it locked all the doors but one or more doors are ajar. As soon as the last door is closed, one
flash of the turn signals occurs. If 2 presses of the LOCK button are received within 3 seconds, the horn chirps
once, and the turn signals flash twice to indicate that all the doors are closed and locked. If any door is ajar
when the second lock request is received within 3 seconds of the first, the RKE feature requests the horn chirp
twice without flashing the turn signals to indicate it locked all the doors, but one or more doors are ajar. When
the key is in the RUN or START position, no turn signals flashes or horn chirp confirmations occur.
Remote Keyless Entry (RKE) Liftgate Glass Release
The RKE feature provides liftgate glass release function (vehicles without power liftgate only) independently
of key position. The liftgate glass release button must be pressed twice within 3 seconds for the liftgate glass
to release.
Remote Keyless Entry (RKE) Power Liftgate
Liftgate Glass 705

The RKE feature provides a power liftgate open/close function independently of key position. The power
liftgate button must be pressed twice within 3 seconds for the power liftgate to open or close.
Panic Alarm
The panic alarm feature controls activation of the panic alarm, providing audible and visual alarms that are
evident from the exterior of the vehicle. The panic alarm feature requests that the turn signals and horn are
flashed until deactivation. The flashing of the outputs occurs at the same time. Activation of the panic alarm is
accomplished by pressing the PANIC button on an IKT whenever the key is in the OFF or ACC position. At
all other times this feature is disabled. Deactivation of an active panic alarm is accomplished by:
a second press of the IKT PANIC button.

the ignition switch transitions out of the OFF or ACC position.
a period of 2 minutes and 45 seconds has elapsed since the initial activation.
Remote Keyless Entry (RKE) Memory Seat Feature
The RKE feature provides a memory seat feature. Up to 2 RKE transmitters can be associated with memory
settings. When the unlock button on an RKE transmitter is pressed, the driver seat, adjustable steering
column, adjustable pedals, and exterior mirrors move to the desired memory position (the seat, steering
column, adjustable pedals and mirror position correspond to the RKE transmitter being used). This feature can
be enabled/disabled. Refer to Remote Memory Activation and Remote Memory Deactivation in this section
for programming information.
Keyless Entry Keypad
The keyless entry keypad (if equipped), located on the exterior of the driver door, provides a method for the
customer to access the vehicle without a key or an RKE transmitter. The keyless entry keypad feature:
Locks all doors

Unlocks the driver door (stepped unlock enabled)
Unlocks all doors
Programs/erases the customer keypad code
Enables/disables auto-locking
Enables/disables auto-unlocking
Releases the liftgate glass
Illuminates the keypad
Illuminates the interior lamps
The keyless entry keypad feature operates independently of ignition status, vehicle speed, or transmission
position. The keypad is inoperative when the driver door is ajar. When a keypad button is pressed, the keypad
buttons illuminate to provide better visibility. If the 7/8 and 9/0 buttons are pressed or 5 seconds have elapsed
since the last button press, the illumination is turned off.
Each vehicle equipped with a keyless entry keypad is programmed with a 5-digit entry code. This code is
provided to the customer on a wallet card in the Owner's Literature package. In addition, this code is available
through a scan tool and printed on the SJB label. When entering codes, each digit must be entered within 5
seconds of the previous button press. In addition to the factory set code, up to 3 personal codes can be
programmed. Refer to Keyless Entry Keypad Code Programming in this section for programming
information.
Anti-Scan Feature
To provide added security, the keyless entry keypad is disabled for 1 minute after pressing any of the buttons
Liftgate Glass 706

35 times without a valid entry code being entered. The keypad flashes during this 1-minute mode with all
functionality disabled except for buttons 7/8 and 9/0 still being allowed to lock the vehicle.
Anti-scan is turned off after any of the following events:
One minute of keyless entry keypad inactivity has elapsed

The IKT UNLOCK button is pressed
The key is turned to the ON position
Unlocking the Doors with the Keyless Entry Keypad System
To unlock the driver door (stepped unlock enabled), enter either the factory set code or the personal code
(each digit must be pressed within 5 seconds of the prior digit). This illuminates the interior lamps.
To unlock all doors, enter either the factory set code or the personal code (driver door unlocks) and press the
3/4 button within 5 seconds. If the stepped unlock is disabled, all the doors unlocks upon the entry of the
factory set or personal code. Refer to Stepped Unlock Programming in this section for programming
information.
To unlatch the liftgate glass, enter either the factory set code or the personal code (each digit must be pressed
within 5 seconds of the prior digit) and press the 5/6 button within 5 seconds.
Locking the Doors with the Keyless Entry Keypad System
It is not necessary to enter the factory set or personal code prior to locking all doors. To lock all doors, press
the 7/8 and 9/0 buttons at the same time with the driver door closed.
Releasing the Liftgate Glass
To release the liftgate glass, enter the factory set code or a personal code and press the 5/6 button within 5
seconds.
Keyless Entry Keypad Memory Seat Feature
The keypad provides a memory seat feature. The feature is associated with personal codes and positions the
driver seat, adjustable steering column, adjustable pedals and exterior mirrors to the Driver 1 or Driver 2
memory setting. Refer to Keyless Entry Keypad Code Programming in this section for programming
information.
Liftgate Glass 707

Liftgate Glass 708


Workshop Manual
Handles, Locks, Latches and Entry Systems
Special Tool(s)


Flex Probe Kit
Material
Item Specification
Multi-Purpose Grease ESB-M1C93-B
XG-4 and/or XL-5
Penetrating and Lock Lubricant (US); -
Penetrating Fluid (Canada)
NOTE: The Smart Junction Box (SJB) is also known as the Generic Electronic Module (GEM).
The SJB receives inputs and delivers outputs to many of the electronically controlled features of the vehicle.
The SJB constantly monitors the system and reports a concern in the form of a DTC.
Power Locks
The SJB monitors the door lock control switches. When the SJB receives an unlock/lock command from
either door lock control switch, the SJB energizes a relay (internal to the SJB ) to supply the correct power
and grounds for the door lock actuators.
Liftgate and Liftgate Glass Release
The SJB monitors the liftgate release switch and the liftgate glass release switch. The doors must be unlocked
electronically in order for the SJB to release the liftgate latch or the liftgate glass latch. When this condition is
met and the SJB receives a request from the liftgate release switch or the liftgate glass release switch, the SJB
provides power to the corresponding latch release motor.
Remote Keyless Entry (RKE)

The SJB interprets radio frequency signals from the Remote Keyless Entry (RKE) transmitters. The SJB
requests the illuminated entry feature to turn the interior lamps on when an unlock command is received. If a
lock command is received, the illuminated entry feature turns off.
The RKE transmitter supplies a signal to the SJB when any button is pressed. The SJB then supplies voltage
to the appropriate door lock actuator(s) to lock or unlock the doors. The RKE transmitter can also be used to
release the liftgate glass (vehicles without power liftgate) or release the power liftgate. The RKE transmitter
can also be used to activate the panic alarm. On vehicles with memory, the RKE transmitter also causes the
SJB to send a Medium Speed Controller Area Network (MS-CAN) message to the Driver Seat Module (DSM)
to activate all memory features to the positions associated with the RKE transmitter being used.
The keyless entry keypad is hardwired to the SJB . The SJB interprets the inputs from the keyless entry
keypad and then controls the associated operation. The keyless entry keypad is illuminated for 5 seconds
when any button is pressed. The SJB requests the illuminated entry feature to turn the interior lamps on when
a valid entry code is received. If a lock all doors code is entered, the illuminated entry feature turns off.
NOTE: The keyless entry keypad does not lock the doors if the driver door is ajar.
The keyless entry keypad supplies a signal to the SJB when the buttons are pressed. The SJB then supplies
voltage to the appropriate door lock actuator(s) to lock or unlock the doors. The keyless entry keypad can also
be used to release the liftgate glass. On vehicles with memory, the keyless entry keypad also causes the SJB to
send an MS-CAN message to the DSM to activate all memory features to the positions associated with the
personal entry code entered in on the keypad.
Field-Effect Transistor (FET) Protection
Field-Effect Transistor (FET) is a type of transistor that when used with module software can be used to
monitor and control current flow on module outputs. The FET protection strategy is used to prevent module
damage in the event of excessive current flow.
The SJB utilizes a FET protective circuit strategy for many of its outputs (for example, a headlamp output
circuit). Output loads (current level) are monitored for excessive current (typically short circuits) and are shut
down (turns off the voltage or ground provided by the module) when a fault event is detected. A continuous
DTC is stored at the fault event and a cumulative counter is started.
When the demand for the output is no longer present, the module resets the FET circuit protection to allow the
circuit to function. The next time the driver requests a circuit to activate that has been shut down by a previous
short ( FET protection) and the circuit remains shorted, the FET protection shuts off the circuit again and the
cumulative counter advances.
When the excessive circuit load occurs often enough, the module shuts down the output until a repair
procedure is carried out. Each FET protected circuit has 3 predefined levels of short circuit tolerance based on
the harmful effect of each circuit fault on the FET and the ability of the FET to withstand it. A module
lifetime level of fault events is established based upon the durability of the FET . If the total tolerance level is
determined to be 600 fault events, the 3 predefined levels would be 200, 400 and 600 fault events.
When each tolerance level is reached, the continuous DTC that was stored on the first failure cannot be
cleared by a command to clear the continuous DTCs. The module does not allow this code to be cleared or the
circuit restored to normal operation until a successful self-test proves that the fault has been repaired. After the
self-test has successfully completed (no on-demand DTCs present), DTC B106E and the associated
continuous DTC (the DTC related to the shorted circuit) automatically clears and the circuit function returns.

When the first or second level is reached, the continuous DTC (associated with the short circuit) sets along
with DTC B106E. These DTCs can be cleared using the module on-demand self-test, then the Clear DTC
operation on the scan tool (if the on-demand test shows the fault corrected). The module never resets the fault
event counter to zero and continues to advance the fault event counter as short circuit fault events occur.
If the number of short circuit fault events reach the third level, then DTCs B106F and B1342 set along with
the associated continuous DTC. This DTC cannot be cleared and the module must be replaced.
The SJB FET protected output circuits for the handles, locks, latches and entry systems are the liftgate lock
actuator circuit CPL10 (GN/WH) and the keypad illumination circuit CPK28 (WH/GN).
Door handles Smart Junction Box (SJB)

Binding latch fuse(s):
mechanisms 5 (10A)
17 (20A)
Wiring, terminals or
connectors
Door lock control switches
Liftgate release switch
Liftgate glass release switch
Integrated Keyhead
Transmitter (IKT)
Keyless entry keypad
SJB
5. NOTE: The Vehicle Communication Module (VCM) LED prove-out confirms power and ground
Check the VCM connection to the vehicle.

Check the scan tool connection to the VCM .

Refer to Section 418-00 , No Power To The Scan Tool, to diagnose no power to the scan tool.

Verify the ignition key is in the ON position.
Verify the scan tool operation with a known good vehicle.
Refer to Section 418-00 to diagnose no response from the PCM.

418-00 .
If the network test passes, retrieve and record the continuous memory DTCs.
8. Clear the continuous DTCs and carry out the self-test diagnostics for the Instrument Cluster (IC), the
SJB , and the Liftgate/Trunk Module (LTM).
9. If the DTCs retrieved are related to the concern, go to DTC Charts. For all other DTCs, refer to the
Diagnostic Trouble Code (DTC) Chart in Section 419-10 .
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart - Electrical .
DTC Charts
Instrument Cluster (IC) DTC Chart

B1137 Data Not GO to Pinpoint Test P .
Programmed
B1138 Memory Full The Smart Junction Box (SJB) has 4 Integrated Keyhead Transmitters (IKTs)
stored in memory and cannot program any more IKTs into the SJB memory.
PROGRAM all of the customer's IKTs (up to 4). REFER to Section 419-01B
.
B1139 Invalid Transmitter GO to Pinpoint Test J .
Identification Code
All other - REFER to the Diagnosticrouble Code (DTC) Chart in Section 419-10 .
DTCs

B1138 Memory Full The Smart Junction Box (SJB) has 4 Integrated Keyhead
Transmitters (IKTs) stored in memory and cannot program
any more IKTs into the SJB memory. PROGRAM all of the
customer's IKTs (up to 4). REFER to Section 419-01B .
B1139 Invalid Transmitter GO to Pinpoint Test J .
Identification Code
B1624 GO to Pinpoint Test I .

Lamp Keypad Output Open

Circuit
B1626 Lamp Keypad Output Short GO to Pinpoint Test I .
Circuit To Ground
B2276 Less Than 2 Transmitters PROGRAM all of the customer's IKTs . REFER to Section
Programmed 419-01B . TEST the system for normal operation.
B2425 Remote Keyless Entry Out of GO to Pinpoint Test J .
Synchronization
B2666 Liftgate Release Switch Circuit GO to Pinpoint Test G .
Failure
B2667 Liftglass Release Switch GO to Pinpoint Test F .
Circuit Failure
B273A Liftgate Release Output Circuit GO to Pinpoint Test G .
Short to Ground
B273B Liftgate Release Output Circuit GO to Pinpoint Test G .
B2A25 Trim Panel Lock Switch Circuit GO to Pinpoint Test E .
Failure
B2A26 Keypad Switch Circuit Failure GO to Pinpoint Test H .
All other - REFER to the Diagnostic Trouble Code (DTC) Chart in
DTCs Section 419-10 .
Symptom Chart - Electrical
Symptom Chart - Mechanical
Pinpoint Tests
Pinpoint Test A: All Door Locks Are Inoperative
Refer to Wiring Diagrams Cell 110 , Power Door Locks for schematic and connector information.
Normal Operation
The Smart Junction Box (SJB) supplies voltage to the lock all relay, the unlock driver door relay or unlock all
relay based upon input from the door lock control switches, the Remote Keyless Entry (RKE) transmitter, or
the keyless entry keypad. Upon a lock request, the SJB supplies voltage on the all door lock circuit and
ground on the driver and passenger door unlock circuits. Upon an unlock request, the voltage and ground are
reversed on the previously listed circuits. When the door lock and unlock relays are not energized they are
connected to ground. A dedicated SJB ground circuit is provided only for the lock and unlock relays.
Fuse
SJB

PINPOINT TEST A: ALL DOOR LOCKS ARE INOPERATIVE
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.
NOTE: Failure to disconnect the battery when instructed will result in false resistance readings. Refer to
Section 414-01 .

A1 CHECK THE RECORDED SJB DTCs FROM THE
SELF-TEST
Yes
Check the recorded results from the SJB self-test. GO to Pinpoint Test E .
Is DTC B2A25 present?
No
GO to A2 .
A2 VERIFY THE OPERATION OF BOTH DOOR LOCK
CONTROL SWITCHES
Yes
Press the LOCK and UNLOCK button of both door lock GO to A3 .
control switches while observing the door lock
operation. No
Are the door locks inoperative from both switches? GO to Pinpoint Test D .
A3 VERIFY ALL DOOR LOCKS ARE INOPERATIVE
Yes
Press the LOCK and UNLOCK buttons from a door VERIFY the SJB fuse 17 (20A) is OK.
lock control switch while observing the door locks. If OK, GO to A4 . If not OK, GO to A6
Are all the door locks inoperative from both switch .
positions (lock and unlock)?
No
GO to Symptom Chart - Electrical .
A4 CHECK THE POWER DOOR LOCK RELAY
Yes
Disconnect: Negative Battery Cable .
Disconnect: SJB C2280d . No
Measure the resistance between the SJB C2280d-7, REPAIR circuit GD138 (BK/WH) for
circuit GD138 (BK/WH), harness side and ground. an open. TEST the system for normal
operation.

A5 CHECK THE ALL LOCK CIRCUIT FOR AN OPEN
PINPOINT TEST A: ALL DOOR LOCKS ARE INOPERATIVE 714

Disconnect: LH Front Door Lock Actuator C525 . Yes

Measure the resistance between the SJB C2280d-6, GO to A9 .
circuit CPL11 (GY/BN), harness side and the LH front
door lock actuator C525-1, circuit CPL11 (GY/BN), No
harness side. REPAIR circuit CPL11 (GY/BN) for
an open. TEST the system for normal
operation.

A6 CHECK THE LIFTGATE GLASS RELEASE
OUTPUT CIRCUIT FOR A SHORT TO GROUND
Yes
Install a new SJB fuse 17 (20A). GO to A8 .
Operate the liftgate glass release by pressing the liftgate
glass release switch. No
Is the SJB fuse 17 (20A) OK? GO to A7 .
A7 CHECK THE LIFTGATE GLASS ACTUATOR FOR
A SHORT
Yes
Install a new SJB fuse 17 (20A). INSTALL a new liftgate glass latch.
Operate the liftgate glass release by pressing the liftgate REFER to Liftgate Latch - Window in
glass release switch. this section. TEST the system for
Is the SJB fuse 17 (20A) OK? normal operation.
No
REPAIR circuit CPL59 (BN/BU) for a
short to ground. TEST the system for
normal operation.
A8 CHECK THE ALL LOCK CIRCUIT FOR A SHORT
TO GROUND
Yes
Operate the door lock actuators by pressing LOCK on REPAIR circuit CPL51 (BU/GN) or
the door lock control switch. circuit CPL52 (VT/GY) for a short to
Is the SJB fuse 17 (20A) OK? ground. TEST the system for normal
operation.
No
REPAIR circuit CPL11 (GY/BN) for a
short to ground. TEST the system for
normal operation.
A9 CHECK FOR CORRECT SJB OPERATION
Yes
Disconnect all the SJB connectors. INSTALL a new SJB . REFER to
Check for: Section 419-10 . TEST the system for
corrosion normal operation.
damaged pins
PINPOINT TEST A: ALL DOOR LOCKS ARE INOPERATIVE 715

pushed-out pins No
Connect all the SJB connectors and make sure they seat The system is operating correctly at
correctly. this time. The concern may have been
Operate the system and verify the concern is still caused by a loose or corroded
present. connector.
Pinpoint Test B: A Single/More Than One Door Lock Is Inoperative
Normal Operation
The Smart Junction Box (SJB) supplies voltage to the lock all relay, the unlock driver door relay or unlock all
relay based upon input from the door lock control switches, the Remote Keyless Entry (RKE) transmitter, or
the keyless entry keypad. Upon a lock request, the SJB supplies voltage on the all door lock circuit and
ground on the driver and passenger door unlock circuits. Upon an unlock request, the voltage and ground are
reversed on the previously listed circuits. When the door lock and unlock relays are not energized they are
connected to ground. A dedicated SJB ground circuit is provided only for the lock and unlock relays.

Door lock actuator
SJB
PINPOINT TEST B: A SINGLE/MORE THAN ONE DOOR LOCK IS INOPERATIVE

B1 CHECK THE DOOR LATCH FOR BINDING
Yes
Lock and unlock the inoperative door lock using the door lock GO to B3 .
rod.
Does the door lock and unlock? No
GO to B2 .
B2 CHECK THE LOCK ROD FOR BINDING
Yes
Operate the door lock rod manually while observing the door lock REPAIR as necessary. TEST
rod for any binding or if the rod is bent. the system for normal
Is the door lock rod bent or binding? operation.
No
INSTALL a new door latch.
REFER to Front Door Latch
or Rear Door Latch in this
normal operation.

B3 CHECK THE ALL LOCK CIRCUIT FOR VOLTAGE

Yes
Disconnect: Inoperative Door Lock Actuator .
NOTE: The SJB only supplies voltage to the actuator No
momentarily. It is important to monitor the meter while pressing REPAIR circuit CPL11
the door lock control switch. (GY/BN) for an open. TEST
While pressing the door lock control switch in the LOCK the system for normal
position, measure the voltage between the inoperative door lock operation.
actuator, harness side and ground as follows:
Inoperative Door Lock

Actuator Connector-Pin Circuit
LH front C525-1 CPL11
(GY/BN)
RH front C603-1 CPL11
(GY/BN)
LH rear C704-1 CPL11
(GY/BN)
RH rear C804-1 CPL11
(GY/BN)
Is the voltage momentarily greater than 10 volts?

B4 CHECK THE UNLOCK CIRCUIT FOR VOLTAGE
Yes
NOTE: The SJB only supplies voltage to the actuator INSTALL a new door lock
momentarily. It is important to monitor the meter while pressing actuator. REFER to Door
the door lock control switch. Lock Actuator in this section.
While pressing the door lock control switch in the UNLOCK TEST the system for normal
position, measure the voltage between the inoperative door lock operation.
actuator, harness side and ground as follows:
No
GO to B5 .
Inoperative Door Lock

Actuator Connector-Pin Circuit
LH front C525-2 CPL51
(BU/GN)
RH front C603-2
PINPOINT TEST B: A SINGLE/MORE THAN ONE DOOR LOCK IS INOPERATIVE 717

CPL52
(VT/GY)
LH rear C704-2 CPL52
(VT/GY)
RH rear C804-2 CPL52
(VT/GY)

B5 CHECK THE UNLOCK CIRCUIT FOR AN OPEN
Yes
Disconnect: SJB C2280d . GO to B6 .
Measure the resistance between the inoperative door lock
actuator, harness side and the SJB , harness side as follows: No
REPAIR circuit CPL51
(BU/GN) or circuit CPL52
(VT/GY) for an open. TEST
Inoperative Door Lock SJB operation
Actuator Connector-Pin Connector-Pin Circuit
LH front C525-2 C2280d-28 CPL51
(BU/GN)
RH front C603-2 C2280d-27 CPL52
(VT/GY)
LH rear C704-2 C2280d-27 CPL52
(VT/GY)
RH rear C804-2 C2280d-27 CPL52
(VT/GY)

B6 CHECK FOR CORRECT SJB OPERATION
Yes
Disconnect all the SJB connectors. INSTALL a new SJB .
Check for: REFER to Section 419-10 .
corrosion TEST the system for normal
PINPOINT TEST B: A SINGLE/MORE THAN ONE DOOR LOCK IS INOPERATIVE 718

damaged pins operation.

pushed-out pins
Connect all the SJB connectors and make sure they seat correctly. No
Is the concern still present? correctly at this time. The
concern may have been
connector.
Pinpoint Test C: The Door Locks Operate Only One Way
Normal Operation
The Smart Junction Box (SJB) sends voltage signals to the door lock control switches through the lock and
unlock input circuits. When the lock or unlock switch is pressed, the corresponding voltage signal is routed to
ground, signaling the SJB to lock or unlock the doors. The door lock control switches have a dedicated ground
circuit.

SJB
PINPOINT TEST C: THE DOOR LOCKS OPERATE ONLY ONE WAY

C1 CHECK THE RECORDED SJB DTCs FROM THE SELF-TEST
Yes
Check the recorded results from the SJB self-test. GO to Pinpoint Test E .
No
GO to C2 .
C2 VERIFY THE OPERATION OF BOTH DOOR LOCK CONTROL
SWITCHES
Yes
Press the LOCK and UNLOCK button of both door lock control
switches while observing the door lock operation. No
Do the door locks operate only one way from both switches? GO to C3 .
C3 CHECK THE LOCK INPUT OR UNLOCK INPUT CIRCUIT FOR
AN OPEN (SINGLE SWITCH INOPERATIVE)

Disconnect: Suspect Door Lock Control Switch . Yes

Unlock the doors from the working door lock control switch. REMOVE the jumper
Connect a fused jumper wire between the LH door lock control switch wire. INSTALL a new
C505-1, circuit CPL27 (WH/BN), harness side and the LH door lock door lock control switch.
control switch C505-4, circuit GD143 (BK/VT), harness side; or TEST the system for
between the RH door lock control switch C605-1, circuit CPL27 normal operation.
(WH/BN), harness side and the RH door lock control switch C605-4,
circuit GD138 (BK/WH), harness side. No
REMOVE the jumper
wire. REPAIR the input
circuit in question. TEST
operation.
Remove the jumper wire.

Connect a fused jumper wire between the LH door lock control switch
C505-3, circuit CPL30 (BU/BN), harness side and the LH door lock
control switch C505-4, circuit GD143 (BK/VT), harness side; or
between the RH door lock control switch C605-3, circuit CPL30
(BU/BN), harness side and the RH door lock control switch C605-4,
circuit GD138 (BK/WH), harness side.
Do the doors lock and unlock with the jumper wire?

C4 CHECK THE LOCK INPUT OR THE UNLOCK INPUT CIRCUIT
FOR AN OPEN (BOTH SWITCHES INOPERATIVE)
Yes
Disconnect: LH Door Lock Control Switch C505 . GO to C5 .
Disconnect: SJB C2280c .
If the doors do not lock, measure the resistance between the SJB No
C2280c-17, circuit CPL27 (WH/BN), harness side and the LH door REPAIR the circuit in
lock control switch C505-1, circuit CPL27 (WH/BN), harness side. question. TEST the
system for normal
operation.
PINPOINT TEST C: THE DOOR LOCKS OPERATE ONLY ONE WAY 720
If the doors do not unlock, measure the resistance between the SJB
C2280c-4, circuit CPL30 (BU/BN), harness side and the LH door
lock control switch C505-3, circuit CPL30 (BU/BN), harness side.

C5 CHECK FOR CORRECT SJB OPERATION
Yes
Check for: REFER to Section
corrosion 419-10 . TEST the
damaged pins system for normal
pushed-out pins operation.
Connect all the SJB connectors and make sure they seat correctly.
Operate the system and verify the concern is still present. No
Is the concern still present? The system is operating
correctly at this time. The
corroded connector.
Pinpoint Test D: All Door Locks Are Inoperative From One Switch
Normal Operation
circuit.

Door lock control switch
PINPOINT TEST D: ALL DOOR LOCKS ARE INOPERATIVE FROM ONE SWITCH

D1 CHECK THE SUSPECT DOOR LOCK

CONTROL SWITCH
Yes
Disconnect: Suspect Door Lock Control REPAIR circuit GD138 (BK/WH) or GD143 (BK/VT)
Switch . for an open. TEST the system for normal operation.
Carry out the door lock control switch
component test. No
INSTALL a new door lock control switch. TEST the
Refer to Wiring Diagrams Cell 149 for system for normal operation.
component testing.
Is the door lock control switch OK?
Pinpoint Test E: DTC B2A25
Normal Operation
circuit.
DTC B2A25 (Trim Panel Lock Switch Circuit Failure) - an on-demand DTC that sets when the SJB
detects a short to ground from the lock or unlock request input circuits. This DTC may also set if
either of the door lock control switches are pressed for longer than 2 minutes.
Wiring, terminals or nnectors

Door lock control switch
SJB
PINPOINT TEST E: DTC B2A25

E1 CHECK THE RECORDED SJB DTCs FROM THE
SELF-TEST
Yes
Check the recorded results from the SJB self-test. GO to E2 .
No
E2 CHECK THE LH DOOR LOCK CONTROL SWITCH
Yes
Disconnect: LH Door Lock Control Switch C505 . LEAVE the switch disconnected. GO
Repeat the SJB self-test. to E3 .
PINPOINT TEST D: ALL DOOR LOCKS ARE INOPERATIVE FROM ONE SWITCH 722
Is DTC B2A25 retrieved again?

No
INSTALL a new LH door lock
control switch. TEST the system for
normal operation.
E3 CHECK THE RH DOOR LOCK CONTROL SWITCH
Yes
Disconnect: RH Door Lock Control Switch C605 . LEAVE the switch disconnected. GO
Repeat the SJB self-test. to E4 .
Is DTC B2A25 retrieved again?
No
INSTALL a new RH door lock
control switch. TEST the system for
normal operation.
E4 CHECK THE LOCK INPUT CIRCUIT OR THE
UNLOCK INPUT CIRCUIT FOR A SHORT TO GROUND
Yes
Measure the resistance between the SJB C2280c-17, No
circuit CPL27 (WH/BN), harness side and ground; and REPAIR the circuit in question.
between the SJB C2280c-4, circuit CPL30 (BU/BN), CLEAR the DTCs. REPEAT the
harness side and ground. self-test.

E5 CHECK FOR CORRECT SJB OPERATION
Yes
damaged pins
pushed-out pins No
Connect all the SJB connectors and make sure they seat The system is operating correctly at
correctly. this time. The concern may have been
Operate the system and verify the concern is still present. caused by a loose or corroded
Is the concern still present? connector.
Pinpoint Test F: The Liftgate Glass Latch Release Is Inoperative/Does Not Operate Correctly
Refer to Wiring Diagrams Cell 117 , Remote Keyless Entry and Alarm for schematic and connector
information.
PINPOINT TEST E: DTC B2A25 723

Normal Operation
When the Smart Junction Box (SJB) receives an open request from the liftgate glass release switch, a Remote
Keyless Entry (RKE) (vehicles without power liftgate) or the keyless entry keypad (if equipped), the SJB
supplies voltage to the liftgate glass latch. The liftgate glass latch has a dedicated ground circuit.
The SJB sends a voltage signal to the liftgate glass release switch through the input circuit. When the liftgate
glass release switch is pressed, the voltage signal is routed to ground, signaling the SJB to release the liftgate
glass. The liftgate glass release switch has a dedicated ground circuit.
DTC B2667 (Liftglass Release Switch Circuit Failure) - a continuous and on-demand DTC that sets
when the SJB detects a short to ground on the liftgate glass release switch input circuit. This DTC
may also set if the liftgate glass release switch is pressed for longer than 2 minutes.

Liftgate glass release switch
Liftgate glass release actuator (integral to the liftgate glass latch)
SJB
PINPOINT TEST F: THE LIFTGATE GLASS LATCH RELEASE IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
NOTICE: Use the correct probe adapter(s) when makingeasurements. Failure to use the correct probe
adapter(s) may damage the connector.
Section 414-01 .

F1 CHECK THE DOOR LOCK OPERATION
Yes
Lock and unlock the doors using a door lock control switch. GO to F2 .
Do the door locks operate correctly?
No
F2 CHECK THE RECORDED SJB DTCs FROM THE
SELF-TEST
Yes
Check the recorded results from the SJB self-test. GO to F3 .
Is DTC B2667 present?
No
GO to F5 .
F3 CHECK THE LIFTGATE GLASS RELEASE SWITCH
(SHORT TO GROUND)
Yes
Disconnect: Liftgate Glass Release Switch C4039 . GO to F4 .
Clear the DTC and carry out the SJB self-test.
Is DTC B2667 still present? No
INSTALL a new liftgate glass
release switch. TEST the system


INPUT CIRCUIT FOR A SHORT TO GROUND
Yes
Measure the resistance between the liftgate glass release switch No
C4039-2, circuit 1760 (WH/VT), harness side and ground. REPAIR circuit 1760 (WH/VT)
for a short to ground. CLEAR
self-test.

F5 MONITOR THE LIFTGATE GLASS RELEASE SWITCH
PID
Yes
Ignition ON. GO to F9 .
Enter the following diagnostic mode on the scan tool: SJB
DataLogger . No
Monitor the SJB liftgate glass release switch PID GO to F6 .
(LIFTGLASS_SW) while pressing the liftgate glass release
switch.
Does the PID indicate the liftgate release switch is active?
Yes
Disconnect: Liftgate Glass Release Switch C4039 . INSTALL a new liftgate glass
Unlock the doors with the door lock control switch. release switch. TEST the system
Connect a fused jumper wire between the liftgate glass release for normal operation.
switch C4039-2, circuit 1760 (WH/VT), harness side and the
liftgate glass release switch C4039-1, circuit 57 (BK), harness No
side. REMOVE the jumper wire. GO
to F7 .
Does the liftgate glass latch release?

F7 CHECK THE GROUND CIRCUIT TO THE SWITCH FOR
AN OPEN
PINPOINT TEST F: THE LIFTGATE GLASS LATCH RELEASE IS INOPERATIVE/DOES NOT OPERATE
725 C
Ignition OFF. Yes

Disconnect: Negative Battery Cable . GO to F8 .
Measure the resistance between the liftgate glass release switch
C4039-1, circuit 57 (BK), harness side and ground. No
REPAIR circuit 57 (BK) for an
normal operation.

F8 CHECK LIFTGATE GLASS RELEASE SWITCH INPUT
CIRCUIT FOR AN OPEN
Yes
Connect a fused jumper wire between the liftgate glass release GO to F14 .
switch C4039-2, circuit 1760 (WH/VT), harness side and the
liftgate glass release switch C4039-1, circuit 57 (BK), harness No
side. REPAIR circuit CPL60
(BN/YE) for an open. TEST the

Measure the resistance between the SJB C2280c-20, circuit
CPL60 (BN/YE), harness side and ground.

F9 CHECK FOR A SHORT TO VOLTAGE TO THE
LIFTGATE GLASS LATCH
Yes
Disconnect: Liftgate Glass Latch C4040 . GO to F10 .
Measure the voltage between the liftgate glass latch C4040-4,
circuit CPL59 (BN/BU), harness side and ground. No
GO to F11 .
726 C

F10 CHECK THE LIFTGATE GLASS LATCH OUTPUT
Yes
Ignition OFF. REPAIR circuit CPL59
Disconnect: SJB C2280d . (BN/BU) for a short to voltage.
Ignition ON. TEST the system for normal
Measure the voltage between the liftgate glass latch C4040-4, operation.
circuit CPL59 (BN/BU), harness side and ground.
No
GO to F14 .

F11 CHECK FOR VOLTAGE TO THE LIFTGATE GLASS
LATCH
Yes
Unlock the doors with the door lock control switch.
NOTE: The SJB only supplies voltage to the liftgate glass No
latch momentarily. It is important to monitor the meter while GO to F12 .
pressing the liftgate glass release switch.
While pressing the liftgate glass release switch, measure the
voltage between the liftgate glass latch C4040-4, circuit CPL59

F12 CHECK THE LIFTGATE GLASS LATCH OUTPUT
CIRCUIT FOR AN OPEN
727 C
Disconnect: SJB C2280d . Yes

Measure the resistance between the SJB C2280d-31, circuit GO to F14 .
CPL59 (BN/BU), harness side and the liftgate glass latch
C4040-4, circuit CPL59 (BN/BU), harness side. No
(BN/BU) for an open. TEST the

F13 CHECK THE GROUND CIRCUIT TO THE LATCH FOR
AN OPEN
Yes
Disconnect: Negative Battery Cable . INSTALL a new liftgate
Measure the resistance between the liftgate glass latch window latch. REFER to
C4040-3, circuit GD150 (BK/WH), harness side and ground. Liftgate Latch - Window in this
normal operation.
No
REPAIR circuit GD150
(BK/WH) for an open. TEST

F14 CHECK FOR CORRECT SJB OPERATION
Yes
Disconnect all the SJB connectors. INSTALL a new SJB . REFER
Check for: to Section 419-10 . TEST the
corrosion system for normal operation.
damaged pins
pushed-out pins No
Connect all the SJB connectors and make sure they seat The system is operating
correctly. correctly at this time. The
Operate the system and verify the concern is still present. concern may have been caused
Is the concern still present? by a loose or corroded
connector.
Pinpoint Test G: The Liftgate Latch Release Is Inoperative/Does Not Operate Correctly
information.
728 C
Normal Operation
When the Smart Junction Box (SJB) receives an open request from the liftgate release switch or Remote
Keyless Entry (RKE) (vehicles with power liftgate), the SJB supplies voltage to the liftgate latch or the
Liftgate/Trunk Module (LTM) (vehicles with power liftgate). The liftgate latch has a dedicated ground circuit.
The SJB sends a voltage signal to the liftgate release switch through the input circuit. When the liftgate
release switch is pressed, the voltage signal is routed to ground, signaling the SJB to release the liftgate. The
liftgate release switch has a dedicated ground circuit.
DTC B2666 (Liftgate Release Switch Circuit Failure) - a continuous and on-demand DTC that sets
when the SJB detects a short to ground on the liftgate release switch input circuit. This DTC may also
set if the liftgate release switch is pressed for longer than 2 minutes.
DTC B273A (Liftgate Release Output Circuit Short to Ground) - a continuous DTC that sets when the
SJB detects a short to ground on the liftgate latch release output circuit.
DTC B273B (Liftgate Release Output Circuit Open or Short to Battery Voltage) - a continuous and
on-demand DTC that sets when the SJB detects an open or short to voltage on the liftgate latch release
output circuit.

Liftgate release switch
Liftgate release actuator (integral to the liftgate latch)
LTM
SJB
PINPOINT TEST G: THE LIFTGATE LATCH RELEASE IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
Section 414-01 .
NOTE: If the liftgate latch fails to open electronically, it can be opened with the mechanical release. Refer to
Liftgate Latch Manual Release in this section.

G1 CHECK THE DOOR LOCK OPERATION
Yes
Lock and unlock the doors using a door lock control switch. GO to G2 .
Do the door locks operate correctly?
No
G2 CHECK THE RECORDED DTCs FROM THE SJB AND LTM
SELF-TESTS
Yes
Check the recorded results from the SJB and LTM self-tests. For any LTM DTC,
Are any DTCs present? REFER to Section
501-03 .

For DTC B2666, GO to

G3 .
For DTC B273A, GO to

G5 .
For DTC B273B, GO to

G7 (manual liftgate) or
GO to G8 (power
liftgate).
For all other DTCs,

REFER to DTC Charts in
this section.
No
GO to G12 .
G3 CHECK THE LIFTGATE RELEASE SWITCH (SHORT TO
GROUND)
Yes
Disconnect: Liftgate Release Switch C4340 . GO to G4 .
Clear the DTC and carry out the SJB self-test.
Is DTC B2666 still present? No
INSTALL a new liftgate
release switch. REFER to
Liftgate Release Switch
in this section. CLEAR
self-test.
G4 CHECK THE LIFTGATE RELEASE SWITCH INPUT CIRCUIT
Yes
Measure the resistance between the liftgate release switch C4340-2, No
circuit CPL45 (BN), harness side and ground. REPAIR circuit CPL45
(BN) for a short to
ground. CLEAR the
DTCs. REPEAT the
self-test.

G5 CHECK THE LIFTGATE LATCH (MANUAL LIFTGATE) OR
THE LTM (SHORT TO GROUND)
Yes
Ignition OFF. For a manual liftgate,
Disconnect: Liftgate Latch C457 or LTM C4174b . INSTALL a new liftgate
Ignition ON. latch. REFER to Liftgate
PINPOINT TEST G: THE LIFTGATE LATCH RELEASE IS INOPERATIVE/DOES NOT OPERATE

730
CORREC
NOTE: It may be normal for DTC B273A to be present when Latch in this section.
carrying out this step and should be ignored. CLEAR the DTCs.
Clear the DTC and carry out the SJB self-test. REPEAT the self-test.
Is DTC B273B present?
For a power liftgate, GO
to G15 .
No
GO to G6 .
G6 CHECK THE LIFTGATE RELEASE OUTPUT CIRCUIT FOR A
SHORT TO GROUND
Yes
Disconnect: SJB C2280d .
For vehicles with a manual liftgate, measure the resistance between No
the liftgate latch C457-1, circuit CPL10 (GN/WH), harness side and REPAIR circuit CPL10
ground. (GN/WH) for a short to
ground. CLEAR the
DTCs. REPEAT the
self-test.
For vehicles with a power liftgate, measure the resistance between the
LTM C4174b-12, circuit CPL10 (GN/WH), harness side and ground.

G7 CHECK THE LIFTGATE RELEASE OUTPUT CIRCUIT FOR
VOLTAGE
Yes
Disconnect: Liftgate Latch C457 .
Disconnect: LTM C4174b (If Equipped) . No
Measure the voltage between the liftgate latch C457-1, circuit CPL10
(GN/WH), harness side and ground; or between the LTM C4174b-12,
circuit CPL10 (GN/WH), harness side and ground.

731
CORREC

G8 CHECK THE LIFTGATE RELEASE OUTPUT CIRCUIT FOR A
SHORT TO VOLTAGE
Yes
Ignition OFF. REPAIR circuit CPL10
Disconnect: SJB C2280d . (GN/WH) for a short to
Ignition ON. voltage. TEST the system
Measure the voltage between the liftgate latch C457-1, circuit CPL10 for normal operation.
(GN/WH), harness side and ground; or between the LTM C4174b-12,
circuit CPL10 (GN/WH), harness side and ground. No
GO to G16 .

G9 CHECK FOR SJB OUTPUT
Yes
Unlock the doors with the door lock control switch.
NOTE: The SJB only supplies voltage for the liftgate latch release No
momentarily. It is important to monitor the meter while activating the GO to G10 .
liftgate release switch.
While activating the liftgate release switch (pull the liftgate release
handle), measure the voltage between the liftgate latch C457-1, circuit
CPL10 (GN/WH), harness side and ground; or between the LTM
C4174b-12, circuit CPL10 (GN/WH), harness side and ground.

G10 CHECK THE LIFTGATE RELEASE OUTPUT CIRCUIT FOR
AN OPEN

732
CORREC
Disconnect: SJB C2280d . Yes

Measure the resistance between the liftgate latch C457-1, circuit GO to G16 .
CPL10 (GN/WH), harness side and the SJB C2280d-15, circuit
CPL10 (GN/WH), harness side; or between the LTM C4174b-12, No
circuit CPL10 (GN/WH), harness side and the SJB C2280d-15, circuit REPAIR circuit CPL10
CPL10 (GN/WH), harness side. (GN/WH) for an open.
CLEAR the DTCs.

G11 CHECK THE LIFTGATE LATCH GROUND CIRCUIT FOR AN
OPEN
Yes
Disconnect: Negative Battery Cable . For a manual liftgate,
Measure the resistance between the liftgate latch C457-2, circuit INSTALL a new liftgate
GD150 (BK/WH), harness side and ground. latch. REFER to Liftgate
Latch in this section.
CLEAR the DTCs.
For a power liftgate, GO

to G15 .
No
(BK/WH) for an open.
CLEAR the DTCs.
G12 CHECK THE LIFTGATE RELEASE SWITCH
Yes
Ignition OFF. INSTALL a new liftgate
Disconnect: Liftgate Release Switch C4340 . release switch. REFER to
Unlock the doors with the door lock control switch. Liftgate Release Switch
Connect a fused jumper wire between the liftgate release switch in this section. TEST the
C4340-2, circuit CPL45 (BN), harness side and the liftgate release system for normal
switch C4340-1, circuit GD150 (BK/WH), harness side. operation.
No
REMOVE the jumper
wire. GO to G13 .
Does the liftgate latch release?

733
CORREC
G13 CHECK THE LIFTGATE RELEASE SWITCH GROUND

CIRCUIT FOR AN OPEN
Yes
Disconnect: Negative Battery Cable . GO to G14 .
Measure the resistance between the liftgate release switch C4340-1,
circuit GD150 (BK/WH), harness side and ground. No
(BK/WH) for an open.
TEST the system for
normal operation.

G14 CHECK THE LIFTGATE RELEASE SWITCH INPUT CIRCUIT
FOR AN OPEN
Yes
Connect a fused jumper wire between the liftgate release switch GO to G16 .
C4340-2, circuit CPL45 (BN), harness side and the liftgate release
switch C4340-1, circuit GD150 (BK/WH), harness side. No
(BN) for an open. TEST
operation.

Measure the resistance between the SJB C2280c-7, circuit CPL45
(BN), harness side and ground.

G15 CHECK FOR CORRECT LTM OPERATION
Yes
corrosion 501-03 . CLEAR the
damaged pins DTCs. REPEAT the
pushed-out pins self-test.
Connect all the LTM connectors and make sure they seat correctly.

734
CORREC

corroded connector.
G16 CHECK FOR CORRECT SJB OPERATION
Yes
corrosion 419-10 . TEST the
damaged pins system for normal
pushed-out pins operation.
corroded connector.
Pinpoint Test H: The Doors Do Not Lock/Unlock Using The Keyless Entry Keypad
information.
Normal Operation
The Smart Junction Box (SJB) monitors for a ground signal on the keyless entry keypad signal input circuits.
When an individual keypad button is pressed, an individual or combination of the input circuits is routed to
ground. The SJB then determines which button was pressed based on which circuit(s) are grounded. The
keypad has a dedicated ground circuit. Once the SJB determines that the 5-digit personal entry code, or the
factory set 5-digit entry code has been entered on the keypad, the SJB then energizes the driver door unlock
relay to unlock the driver door.
To unlock all the doors and liftgate, the 3/4 button must be pressed within 5 seconds of the 5-digit code being
entered.
To lock all the doors and liftgate, the 5-digit code does not need to be entered. Press the 7/8 and 9/0 buttons at
the same time, with the driver door closed.
To open the liftglass, the 5/6 button must be pressed within 5 seconds of the 5-digit code being entered.
The keyless entry keypad has an anti-scan feature to help prevent theft. If a valid 5-digit code is not entered
within 7 attempts (35 consecutive button presses), the keyless entry keypad goes into anti-scan mode. In
anti-scan mode, the keypad illumination flashes and all input is ignored except for pressing the 7/8 and 9/0
buttons, which locks all the doors.
DTC B2A26 (Keypad Switch Circuit Failure) - a continuous and on-demand DTC that sets when the
SJB detects a short to ground on any of the keypad input circuits. This DTC may also set if any of the
keypad buttons are pressed for longer than 2 minutes.


SJB
PINPOINT TEST H: THE DOORS DO NOT LOCK/UNLOCK USING THE KEYLESS ENTRY KEYPAD
Section 414-01 .
Test StepResult / Action to Take H1 CHECK THE SJB PID (KEYCODE)
Enter the following diagnostic mode on the scan tool: SJB DataLogger .
Observe the SJB PID (KEYCODE). Read and record the 5-digit factory set entry code.
Enter the 5-digit factory set entry code on the keyless entry keypad.
Do the doors unlock?
Yes
The system is operating as designed. INFORM the customer of the correct system operation.
No
GO to H2 . H2 RETRIEVE THE RECORDED SJB DTCs FROM THE SELF-TEST
Check for recorded SJB DTCs from the self-test.

Is DTC B2A26 recorded?
Yes
GO to H3 .
No
GO to H4 . H3 REPEAT THE SJB SELF-TEST
Disconnect: Keyless Entry Keypad C500 .

Clear the DTCs, then repeat the SJB self-test.
Is DTC B2A26 recorded?
Yes
GO to H9 .
No
INSTALL a new keyless entry keypad. REFER to Keyless Entry Keypad in this section. CLEAR the DTCs.
REPEAT the self-test. H4 CHECK THE SJB PID (KEY_PAD)
Enter the following diagnostic mode on the scan tool: SJB DataLogger .
Press each keyless entry keypad button while observing the SJB PID (KEY_PAD) .
Does the PID display the correct values?
Yes
GO to H10 .
No
736
GO to H5 . H5 CHECK THE KEYPAD GROUND CIRCUIT FOR AN OPEN
Disconnect: Negative Battery Cable .

Measure the resistance between the keyless entry keypad C500-5, circuit GD133 (BK), harness side
and ground.
Yes
GO to H6 .
No
REPAIR circuit GD133 (BK) for an open. TEST the system for normal operation. H6 CHECK THE
KEYLESS ENTRY KEYPAD
Connect: Negative Battery Cable .

Connect a fused jumper wire between the keyless entry keypad, harness side, while monitoring the
SJB PID (KEY_PAD) as follows:
Keyless Entry Keypad Keyless Entry Keypad SJB PID (KEY_PAD)

Connector-Pin/ Circuit Connector-Pin/ Circuit Value
C500-1 C500-5 1/2
CPK29 (GY/BU) GD133 (BK)

C500-3 C500-5 7/8
CPK30 (VT/GN) GD133 (BK)

C500-6 C500-5 9/0
CPK31 (YE/GN) GD133 (BK)
Does the PID display the correct values?
737
Yes
INSTALL a new keyless entry keypad. REFER to Keyless Entry Keypad in this section.
No
REMOVE the jumper wire. GO to H7 . H7 CHECK THE KEYPAD INPUT CIRCUITS FOR AN OPEN

Measure the resistance between the SJB , harness side and the keyless entry keypad, harness side as
follows:
SJB Connector-Pin Circuit Keyless Entry Keypad Connector-Pin

C2280c-5 CPK29 (GY/BU) C500-1
C2280c-18 CPK30 (VT/GN) C500-3
C2280c-6 CPK31 (YE/GN) C500-6
Yes
GO to H8 .
No
REPAIR the circuit in question. TEST the system for normal operation. H8 CHECK THE KEYPAD
INPUT CIRCUITS FOR A SHORT TO EACH OTHER
Measure the resistance between the SJB , harness side as follows:
SJB Connector-Pin Circuits SJB Connector-Pin

C2280c-5 CPK29 (GY/BU) C2280c-18
CPK30 (VT/GN)
C2280c-5 CPK29 (GY/BU) C2280c-6
CPK31 (YE/GN)
C2280c-18 CPK30 (VT/GN) C2280c-6
CPK31 (YE/GN)
738
Yes
GO to H9 .
No
REPAIR the circuit in question. TEST the system for normal operation. H9 CHECK THE KEYPAD
INPUT CIRCUITS FOR A SHORT TO GROUND
Ignition OFF.
Measure the resistance between the SJB , harness side and ground as follows:
SJB Connector-Pin Circuit

C2280c-5 CPK29 (GY/BU)
C2280c-18 CPK30 (VT/GN)
C2280c-6 CPK31 (YE/GN)
Yes
GO to H10 .
No
REPAIR the circuit in question. CLEAR the DTCs. REPEAT the self-test. H10 CHECK FOR CORRECT
SJB OPERATION
Disconnect all the SJB connectors.

Check for:
corrosion
damaged pins
pushed-out pins
Operate the system and verify the concern is still present.
739
Yes
INSTALL a new SJB . REFER to Section 419-10 . TEST the system for normal operation.
No
The system is operating correctly at this time. The concern may have been caused by a loose or corroded
connector.
Pinpoint Test I: The Keyless Entry Keypad Illumination Is Inoperative/Does Not Operate Correctly
information.
Normal Operation
When any keypad button is pressed the Smart Junction Box (SJB) sends voltage to the keyless entry keypad
LEDs on the illumination circuit to assist the driver in entering an access code at night. The keyless entry
keypad has a separate ground circuit for the LEDs.
The keyless entry keypad has an anti-scan feature to help prevent theft. If a valid 5-digit code is not entered
within 7 attempts (35 consecutive button presses), the keyless entry keypad goes into anti-scan mode. In
anti-scan mode, the keypad illumination flashes and all input is ignored except for pressing the 7/8 and 9/0
buttons, which locks all the doors.
DTC B1624 (Lamp Keypad Output Open Circuit) - a continuous and on-demand DTC that sets when
the SJB detects the keyless entry keypad illumination output circuit is open or shorted to voltage.
DTC B1626 (Lamp Keypad Output Short Circuit To Ground) - an on-demand DTC that sets when the
SJB detects the keyless entry keypad illumination outpircuit is shorted to ground.

SJB
PINPOINT TEST I: THE KEYLESS ENTRY KEYPAD ILLUMINATION IS INOPERATIVE/DOES NOT OPERATE
CORRECTLY
Section 414-01 .

I1 CHECK THE KEYLESS ENTRY KEYPAD
OPERATION
Yes
Observe the door locks while pressing the keyless entry GO to I2 .
keypad 7/8 and 9/0 buttons.
Do the doors lock? No

I2 CHECK THE RECORDED SJB DTCs FROM THE

SELF-TEST
Yes
Check the recorded results from the SJB self-test. For DTC B1624, GO to I3 .
Is DTC B1624 or DTC B1626 present?
For DTC B1626, GO to I9 .
No
GO to I11 .
I3 CHECK THE KEYLESS ENTRY KEYPAD
ILLUMINATION
Yes
Check the keyless entry keypad illumination.
Is the keyless entry keypad illumination always on? No
GO to I4 .
I4 CHECK THE KEYPAD ILLUMINATION CIRCUIT
FOR REFERENCE VOLTAGE
Yes
NOTE: The SJB sends out a constant reference voltage GO to I5 .
on circuit CPK28 (WH/GN) for its own circuit
diagnostics. This voltage is 10 volts (+/- 1 volt). No
GO to I7 .
Measure the voltage between the keyless entry keypad
C500-2, circuit CPK28 (WH/GN), harness side and
ground.
Is 10 volts (+/- 1 volt) present?

I5 CHECK FOR SJB OUTPUT
Yes
Enter the following diagnostic mode on the scan tool: GO to I6 .
SJB DataLogger .
Measure the voltage between the keyless entry keypad No
C500-2, circuit CPK28 (WH/GN), harness side and GO to I11 .
ground while active commanding the SJB PID
(KY_PAD_LMP) on.
PINPOINT TEST I: THE KEYLESS ENTRY KEYPAD ILLUMINATION IS INOPERATIVE/DOES NOT

741 OPER

I6 CHECK THE KEYPAD ILLUMINATION GROUND
CIRCUIT FOR AN OPEN
Yes
Disconnect: Negative Battery Cable . INSTALL a new keyless entry keypad.
Measure the resistance between the keyless entry REFER to Keyless Entry Keypad in
keypad C500-4, circuit GD143 (BK/VT), harness side this section. CLEAR the DTCs.
and ground. REPEAT the self-test.
No
REPAIR circuit GD143 (BK/VT) for
an open. CLEAR the DTCs. REPEAT
the self-test.

FOR AN OPEN
Yes
Disconnect: SJB C2280c . GO to I11 .
Measure the resistance between the keyless entry
keypad C500-2, circuit CPK28 (WH/GN), harness side No
and the SJB C2280c-11, circuit CPK28 (WH/GN), REPAIR circuit CPK28 (WH/GN) for
harness side. an open. CLEAR the DTCs. REPEAT
the self-test.

Yes
Disconnect: SJB C2280c . REPAIR circuit CPK28 (WH/GN) for a
Ignition ON. short to voltage. CLEAR the DTCs.
Observe the keypad illumination. REPEAT the self-test.
Is the keypad still illuminated?
No
GO to I11 .
PINPOINT TEST I: THE KEYLESS ENTRY KEYPAD ILLUMINATION IS INOPERATIVE/DOES NOT

742 OPER
I9 CHECK THE KEYLESS ENTRY KEYPAD FOR A

SHORT TO GROUND
Yes
Disconnect: Keyless Entry Keypad C500 . GO to I10 .
NOTE: DTC B1624 may set and should be ignored
when carrying out this step. No
Clear the DTCs, then repeat the SJB self-test. INSTALL a new keyless entry keypad.
Is DTC B1626 recorded? REFER to Keyless Entry Keypad in
normal operation.
Yes
Measure the resistance between the keyless entry No
keypad C500-2, circuit CPK28 (WH/GN), harness side REPAIR circuit CPK28 (WH/GN) for a
and ground. short to ground. CLEAR the DTCs.

I11 CHECK FOR CORRECT SJB OPERATION
Yes
damaged pins
pushed-out pins No
Connect all the SJB connectors and make sure they seat The system is operating correctly at this
correctly. time. The concern may have been
present. connector.
Pinpoint Test J: The Remote Keyless Entry (RKE) Transmitter Is Inoperative
Normal Operation
Remote locking and unlocking of the doors is accomplished by the Smart Junction Box (SJB) receiving a
command message from the Remote Keyless Entry (RKE) Integrated Keyhead Transmitter (IKT). The SJB
energizes the appropriate relays to lock or unlock the doors. The RKE transmitters and the SJB also utilize a
rolling code to prevent the code from being "captured" by a code grabber. The system advances the counter in
the RKE transmitter and the SJB every time an RKE transmitter button is pressed.

DTC B1139 (Invalid Transmitter Identification Code) - a continuous DTC that sets when the
Instrument Cluster (IC) or SJB detects an invalid Transmitter Identification Code (TIC) from an IKT .
DTC B2425 (Remote Keyless Entry Out of Synchronization) - a continuous DTC that sets when the
SJB detects the rolling counter received from an RKE transmitter is 1,024 times greater than the
rolling counter stored in the module.
IKT
IKT battery
IKT button pressed a substantial amounttimes while outside the range of the vehicle
IKT programming
SJB
PINPOINT TEST J: THE RKE TRANSMITTER IS INOPERATIVE
NOTE: Aftermarket or dealer-installed systems can adversely affect the RKE system operation. These
systems should be disconnected before diagnosing any RKE concerns.

J1 CHECK FOR THE CORRECT RKE
TRANSMITTERS
Yes
NOTE: Make sure the IKTs are those provided GO to J2 .
with the OEM system and not from an
aftermarket system, or a dealer-installed No
system that may have been installed on the The system cannot be tested without the correct
vehicle. IKTs . INFORM the customer that all the
correct IKTs must be present to proceed with
Check that the correct IKTs are used with the diagnosis of the system.
vehicle. Compare the IKTs with the one shown
in Handles, Locks, Latches and Entry Systems
in the Description and Operation portion of this
section.
Are all the correct IKTs present?
J2 CHECK THE RECORDED SJB AND IC DTCs
FROM THE SELF-TESTS
Yes
Check the recorded results from the SJB and If SJB DTC B2425 is present, GO to J3 .
IC self-tests.
Are any DTCs recorded? If DTC B1139 is present, GO to J5 .
For all other DTCs, REFER to DTC Charts in

this section.
No
GO to J5 .
J3 RESYNCHRONIZE THE INOPERATIVE IKT
Yes
Ignition ON.
PINPOINT TEST J: THE RKE TRANSMITTER IS INOPERATIVE 744

Leave the IKT key in the ON position for a No

minimum of 6 seconds. REFER to Section 419-01B to diagnose the
Start the vehicle. Passive Anti-Theft System (PATS).
Does the vehicle start?
J4 CHECK THE IKT OPERATION
Yes
Ignition OFF. The system is OK. CLEAR the DTCs. REPEAT
Press any button on the IKT . the self-test.
Does the IKT operate?
No
GO to J5 .
J5 MAKE SURE THE RKE TRANSMITTER
SIGNAL IS BEING RECEIVED
Yes
Enter the following diagnostic mode on the GO to J6 .
scan tool: SJB DataLogger .
Press a button on the IKT while observing the No
SJB PIDs (TIC_LAST and TNSMT_CMD). GO to J7 .
Does the TIC and RKE command show up
on the scan tool screen when a button is
pressed?
J6 CHECK IF THE RKE TRANSMITTERS ARE
PROGRAMMED
Yes
Enter the following diagnostic mode on the GO to J9 .
scan tool: SJB DataLogger .
Press a button on the IKT and compare the SJB No
PID (TIC_LAST) with the PIDs (TIC_1, 2, 3, PROGRAM the inoperative IKT or all of the
4, 7, 8, 9, or 10). IKTs . REFER to Section 419-01B . INFORM
Does the TIC displayed match any of the the customer that any IKTs not present need to
TICs stored in memory? be programmed. TEST the system for normal
operation.
J7 CHECK THE IKT BATTERY
Yes
Using a thin coin, open the IKT . GO to J8 .
Do not clean off any grease from the battery
terminals on the back surface of the circuit No
board. INSTALL a new battery (make sure the battery
Verify the correct battery is used (CR2032). is seated correctly). DO NOT reprogram the
Remove the IKT battery and measure the IKT (weak or dead batteries do not erase TICs
voltage. from memory). TEST the system for normal
Is the voltage greater than 2.5 volts? operation.
J8 CHECK FOR NORMAL OPERATION WITH
A KNOWN GOOD IKT
Yes
Enter the following diagnostic mode on the REPLACE the inoperative IKT . PROGRAM
scan tool: SJB DataLogger . the new IKT . REFER to Section 419-01B .
Using the customer's second IKT press a button TEST the system for normal operation.
on the IKT while observing the SJB PID
(TIC_LAST). No
Does the TIC show up on the scan tool when GO to J9 .
a button is pressed?
PINPOINT TEST J: THE RKE TRANSMITTER IS INOPERATIVE 745

J9 CHECK FOR CORRECT SJB OPERATION

Yes
Disconnect all the SJB connectors. INSTALL a new SJB . REFER to Section
Check for: 419-10 . TEST the system for normal operation.
corrosion
damaged pins No
pushed-out pins The system is operating correctly at this time.
Connect all the SJB connectors and make sure The concern may have been caused by a loose
they seat correctly. or corroded connector.
Operate the system and verify the concern is
still present.
Pinpoint Test K: An Individual Button/Feature Is Inoperative From The Remote Keyless Entry (RKE)
Transmitter
Normal Operation
When any Remote Keyless Entry (RKE) Integrated Keyhead Transmitter (IKT) button is pressed, the Smart
Junction Box (SJB) receives the command. The SJB processes the command and energizes the appropriate
relays to lock or unlock the doors, open/close the power liftgate, release the liftgate glass (vehicles without
power liftgate), or activate the turn signals and horn for the panic alarm.
Door locks
Power liftgate
Liftgate glass latch release
Turn signal system
Horn system
IKT
PINPOINT TEST K: AN INDIVIDUAL BUTTON/FEATURE IS INOPERATIVE FROM THE RKE TRANSMITTER
NOTE: The panic feature only operates when the key is in the OFF position.

K1 VERIFY THE DOOR LOCK OPERATION
Yes
Press the LOCK and UNLOCK button from the GO to K2 .
driver door lock control switch while observing
the door lock operation. No
Do the door locks operate correctly? GO to Symptom Chart - Electrical .
K2 VERIFY THE HORN OPERATION
Yes
Enter the following diagnostic mode on the scan GO to K3 .
tool: SJB DataLogger .
Select the SJB PID (HORN) and active command No
the horn on. REFER to Section 413-06 .
Does the horn sound when commanded on?

K3 VERIFY THE HAZARD LAMP OPERATION

Yes
Place the hazard switch in the ON position. GO to K4 .
Do the hazard lamps operate correctly?
No
K4 VERIFY THE LIFTGATE GLASS LATCH
OPERATION
Yes
NOTE: The doors must be unlocked GO to K5 .
electronically before verifying the liftgate glass
release operation. No
Press the liftgate glass release button on the GO to Pinpoint Test F .
liftgate.
Does the liftgate glass release?
K5 VERIFY THE LIFTGATE LATCH
OPERATION
Yes
NOTE: The doors must be unlocked REPLACE the inoperative IKT . PROGRAM
electronically before verifying the liftgate release the new IKT . REFER to Section 419-01B .
operation. TEST the system for normal operation.
Press the liftgate release button on the liftgate.
Does the liftgate release? No
GO to Pinpoint Test G .
Pinpoint Test L: The Remote Keyless Entry (RKE) Transmitter Has Poor Range Performance
Normal Operation
The Remote Keyless Entry (RKE) Integrated Keyhead Transmitter (IKT) sends a radio signal to the Smart
Junction Box (SJB) based on the user selected IKT button. The SJB then carries out the selected action. The
RKE transmitter has a normal operating range of 10 m (33 ft).
Environmental interference
IKT
IKT battery
SJB
PINPOINT TEST L: THE RKE TRANSMITTER HAS POOR RANGE PERFORMANCE
NOTE: All IKTs must be present to begin diagnosis of the RKE system.
NOTE: Aftermarket or dealer-installed systems can adversely affect RKE system operation. These systems
should be disconnected before diagnosing any RKE concerns.

L1 CHECK FOR THE CORRECT RKE
TRANSMITTERS
PINPOINT TEST K: AN INDIVIDUAL BUTTON/FEATURE IS INOPERATIVE FROM THE RKE TRANSMITT

747
NOTE: Make sure the IKTs are those provided with Yes
the OEM system and not from an aftermarket system, GO to L2 .
or a dealer-installed system that may have been
installed on the vehicle. No
The system cannot be tested without the
Check that the correct IKTs are used with the vehicle. correct IKTs . INFORM the customer
Compare the IKTs with the one shown in Handles, that all the correct IKTs must be present
Locks, Latches and Entry Systems in the Description to proceed with diagnosis of the system.
and Operation portion of this section.
L2 CHECK ALL THE IKTs FOR POOR RANGE
PERFORMANCE
Yes
NOTE: The 10 m (33 ft) measurement of range is not GO to L4 .
the standard but is a guideline that clearly indicates a
vehicle is experiencing normal range performance. No
GO to L3 .
Check all the IKTs for poor range performance (10 m
[33 ft] or less).
Do all IKTs experience poor range?
L3 CHECK THE IKT TRANSMITTER BATTERY
Yes
Using a thin coin, open the IKT transmitter. REPLACE the inoperative IKT .
Do not clean off any grease from the battery terminals PROGRAM the new IKT . REFER to
on the back surface of the circuit board. Section 419-01B . TEST the system for
Verify the correct battery is used (CR2032). normal operation.
Remove the RKE transmitter battery and measure the
voltage. No
Is the voltage greater than 2.5 volts? INSTALL a new battery (make sure the
battery is seated correctly). DO NOT
reprogram the IKT (weak or dead
batteries do not erase TICs from
memory). TEST the system for normal
operation.
L4 CHECK THE LOCATION OF THE VEHICLE AND
THE APPROACH ANGLES AROUND THE VEHICLE
Yes
Make sure the poor performance is consistent in nature GO to L5 .
and is not from one approaching angle.
The IKT range performance may be degraded in certain No
locations. For example, if the vehicle is within 0.8 km The system is operating correctly at this
(0.5 miles) of high-power devices or radio/TV towers, time. TEST the system for normal
the operating distance of the IKTs may be reduced. operation.
Is the poor range performance consistent around
the vehicle?
L5 CHECK FOR CORRECT SJB OPERATION
Yes
damaged pins
pushed-out pins No
PINPOINT TEST L: THE RKE TRANSMITTER HAS POOR RANGE PERFORMANCE 748
Connect all the SJB connectors and make sure they seat The system is operating correctly at this
correctly. time. The concern may have been
present. connector.
Pinpoint Test M: The Autolock Does Not Operate Correctly
information.
Normal Operation
The Smart Junction Box (SJB) energizes the lock relay based on input from the ajar switches, the ignition
switch position, the Transmission Range (TR) sensor and the vehicle speed signal. The TR and vehicle speed
signals are sent to the SJB over the Medium Speed Controller Area Network (MS-CAN) from the Instrument
Cluster (IC). The SJB locks the doors when the following conditions are met:
All the doors are closed

The ignition switch is in the RUN position
The vehicle is shifted into any gear putting the vehicle in motion
The vehicle attains a speed greater than 20 km/h (12 mph)

Programming
Door ajar switches
SJB
PINPOINT TEST M: THE AUTOLOCK DOES NOT OPERATE CORRECTLY

M1 VERIFY THE AUTOLOCK FEATURE IS
ENABLED
Yes
Verify the autolock feature is enabled. Refer to GO to M2 .
Autolock and Auto-Unlock Programming in this
section. No
Is the autolock feature enabled? PROGRAM the autolock feature. REFER to
Autolock and Auto-Unlock Programming in
this section.
M2 CHECK THE COURTESY LAMP
OPERATION
Yes
Open and close the doors while checking the GO to M3 .
courtesy lamp operation.
Do the courtesy lamps operate correctly? No
M3 CHECK THE SJB PID (IGN_R_ECU)


tool: SJB DataLogger . GO to M4 .
Ignition ON.
Monitor the SJB IGN PID (IGN_R_ECU). No
Does the PID indicate RUN? REFER to Section 211-05 .
M4 RETRIEVE THE RECORDED SJB DTCs
FROM THE SELF-TEST
Yes
Check for recorded SJB DTCs from the self-test. REFER to Section 418-00 .
Is DTC U0155 recorded?
No
GO to M5 .
M5 CHECK FOR CORRECT SJB OPERATION
Yes
Check for: 419-10 . Test the system for normal operation
corrosion
damaged pins No
pushed-out pins The system is operating correctly at this time.
Connect all the SJB connectors and make sure The concern may have been caused by a loose
they seat correctly. or corroded connector.
Operate the system and verify the concern is still
present.
Pinpoint Test N: The Smart Unlock Does Not Operate Correctly
Normal Operation
The Smart Junction Box (SJB) automatically unlocks all the doors after the doors are locked with a door lock
control switch if the key is in the ignition lock cylinder and one of the front doors is ajar.
The vehicle can still be locked by locking the doors with the push button rods, the door lock cylinder or a
Remote Keyless Entry (RKE) command from an Integrated Keyhead Transmitter (IKT) or the keyless entry
keypad.
Key-in-ignition switch
Door ajar switch input
SJB
PINPOINT TEST N: THE SMART UNLOCK DOES NOT OPERATE CORRECTLY

N1 CHECK THE DOOR LOCK
OPERATION
Yes
Check the operation of the door locks GO to N2 .
from the driver door lock control switch.
PINPOINT TEST M: THE AUTOLOCK DOES NOT OPERATE CORRECTLY 750

Do all the doors lock and unlock? No

N2 CHECK THE COURTESY LAMP
OPERATION
Yes
Open and close the left and right front GO to N3 .
doors while checking the courtesy lamp
operation. No
Do the courtesy lamps operate REFER to Section 417-02 .
correctly?
N3 CHECK THE KEY-IN-IGNITION
CHIME
Yes
Insert the key in the ignition switch. GO to N4 .
Open the driver door.
Does the key-in-ignition chime operate No
correctly? REFER to Section 413-01 .
N4 CHECK FOR CORRECT SJB
OPERATION
Yes
Disconnect all the SJB connectors. INSTALL a new SJB . REFER to Section 419-10 .
Check for: TEST the system for normal operation.
corrosion
damaged pins No
pushed-out pins The system is operating correctly at this time. The
Connect all the SJB connectors and make concern may have been caused by a loose or corroded
sure they seat correctly. connector.
Pinpoint Test O: The Auto-Unlock Does Not Operate Correctly
Normal Operation
The Smart Junction Box (SJB) energizes the unlock relay based on input from the door ajar switches and the
vehicle speed signal. The SJB unlocks the doors when the following conditions are met:
The vehicle speed has exceeded 20 km/h (12 mph) then dropped to 0 km/h (0 mph)
The key is turned to the OFF or ACC position
The LH front door is opened within 10 minutes of the key being turned to the OFF or ACC position
The auto-unlock feature is cancelled if the doors are locked with the door lock control switch or the Remote
Keyless Entry (RKE) transmitter within the 10-minute active window. After the 10-minute active window
expires, the auto-unlock feature does not unlock the doors if the driver door is opened.
The Instrument Cluster (IC) sends the vehicle speed signal over the Medium Speed Controller Area Network
(MS-CAN) to the SJB .
Door ajar switch input
PINPOINT TEST N: THE SMART UNLOCK DOES NOT OPERATE CORRECTLY 751
Vehicle speed signal message
SJB
PINPOINT TEST O: THE AUTO-UNLOCK DOES NOT OPERATE CORRECTLY

O1 VERIFY THE AUTO-UNLOCK
FEATURE IS ENABLED
Yes
Verify the auto-unlock feature is enabled. GO to O2 .
Refer to Autolock and Auto-Unlock
Programming in this section. No
Is the auto-unlock feature enabled? ENABLE the auto-unlock feature. REFER to
Autolock and Auto-Unlock Programming in this
section.
O2 CHECK THE COURTESY LAMP
OPERATION
Yes
Open and close the doors while observing GO to O3 .
the courtesy lamp operation.
Do the courtesy lamps operate correctly? No
O3 CHECK THE VEHICLE SPEED
OPERATION
Yes
Check the operation of the speedometer. GO to O4 .
Does the speedometer operate correctly?
No
O4 CHECK FOR CORRECT SJB
OPERATION
Yes
corrosion
damaged pins No
pushed-out pins The system is operating correctly at this time. The
Connect all the SJB connectors and make concern may have been caused by a loose or
sure they seat correctly. corroded connector.
Operate the system and verify the concern
is still present.
Pinpoint Test P: DTC B1137
Normal Operation
When an Integrated Keyhead Transmitter (IKT) key is programmed, the Remote Keyless Entry (RKE)
Transmitter Identification Code (TIC) data from the key is received by the Instrument Cluster (IC). The IC
then sends the TIC data to the Smart Junction Box (SJB) over the Medium Speed Controller Area Network

(MS-CAN). The SJB stores the TIC data in memory and sends an acknowledgement back to the IC that the
TIC data was successfully programmed.
DTC B1137 (Data Not Programmed) - a continuous DTC that sets when the IC sends the RKE TIC
data to the SJB over the MS-CAN , and it does not receive a response from the SJB that the TIC data
has been stored.
IKT programming
MS-CAN
SJB
PINPOINT TEST P: DTC B1137

P1 CHECK FOR THE CORRECT RKE
TRANSMITTERS
Yes
NOTE: Make sure the IKTs are those provided GO to P2 .
with the OEM system and not from an aftermarket
system, or a dealer-installed system that may have No
been installed on the vehicle. The system cannot be tested without the
correct IKTs . INFORM the customer that
Check that the correct IKTs are used with the all the correct IKTs must be present to
vehicle. Compare the IKTs with the one shown in proceed with diagnosis of the system.
Handles, Locks, Latches and Entry Systems in the
Description and Operation portion of this section.
P2 CHECK FOR COMMUNICATION WITH THE
IC AND SJB
Yes
Enter the following diagnostic mode on the scan REFER to Section 418-00 .
tool: Network Test .
Does the IC or SJB fail the network test? No
GO to P3 .
P3 REPROGRAM THE IKT KEYS
Yes
Erase and program all of the IKT keys using the GO to P5 .
scan tool method. Refer to Section 419-01B .
Erase all IC DTCs. No
Enter the following diagnostic mode on the scan GO to P4 .
tool: IC Self-Test .
Is DTC B1137 retrieved again?
P4 CHECK THE OPERATION OF THE RKE
TRANSMITTER
Yes
Press any button on the suspect IKT key. The system is operating normally. The
Does the RKE transmitter operate? concern may have been caused by an
incorrectly programmed IKT key.

No
P5 CHECK FOR CORRECT SJB OPERATION
Yes
Check for: 419-10 . TEST the system for normal
corrosion operation.
damaged pins
pushed-out pins No
Connect all the SJB connectors and make sure they The system is operating correctly at this
seat correctly. time. The concern may have been caused by
Operate the system and verify the concern is still a loose or corroded connector.
present.
Pinpoint Test Q: Hard To Open/Close Door From Either Door Handle
Normal Operation
The door latch can be actuated from the interior or exterior door handle. When actuated, the door latch
releases and allows the door to open. If the door latch or the door hinges have insufficient lubrication or if the
striker or door are misaligned, it causes extra force to be used when opening or closing the door.
Door alignment
Door hinges
Striker adjustment
Door latch
PINPOINT TEST Q: HARD TO OPEN/CLOSE DOOR FROM EITHER DOOR HANDLE

Q1 CHECK THE LATCH OPERATION
FROM BOTH DOOR HANDLES
Yes
Open the door using both the interior If the door is difficult/does not open from the exterior
and exterior door handles. door handle, GO to Pinpoint Test R .
Does the door open normally from
one of the door handles? If the door is difficult/does not open from the interior
door handle, GO to Pinpoint Test S .
No
If the door does not operate correctly from both door
handles, GO to Q2 .
PINPOINT TEST P: DTC B1137 754

Open the door. Yes

Using a screwdriver, fully close the GO to Q4 .
latch (2 clicks).
No
GO to Q3 .
Verify that the latch releases easily

while pulling on the interior/exterior
door handle.
Does the latch release easily?
AFTER LUBRICATION
Yes
Lubricate the door latch. Refer to Latch The concern was caused by an insufficiently lubricated
Lubrication in this section. door latch.
Using a screwdriver, fully close the
latch (2 clicks). No
INSTALL a new door latch. REFER to Front Door
Latch or Rear Door Latch in this section. TEST the
Verify that the latch releases easily

while pulling on the interior/exterior
door handle.
Does the latch release easily?
Q4 CHECK THE STRIKER
ADJUSTMENT
Yes
Check the adjustment of the striker. GO to Q5 .
Refer to Section 501-03 .
Is the striker adjusted correctly? No
ADJUST the striker as necessary. TEST the system for
normal operation.
Q5 CHECK THE DOOR ALIGNMENT
Yes
Check the alignment of the door. Refer LUBRICATE the door hinges. TEST the system for
to Section 501-03 . normal operation.
Is the door aligned correctly?
No
ADJUST the door as necessary. TEST the system for
normal operation.
PINPOINT TEST Q: HARD TO OPEN/CLOSE DOOR FROM EITHER DOOR HANDLE 755
Pinpoint Test R: A Door Is Difficult/Does Not Open From The Exterior Door Handle
Normal Operation
The exterior door handle is connected to the door latch with an actuating rod. When the exterior door handle is
pulled it causes the actuating rod to push down on the latch lever. The actuating rod can be adjusted for
correct exterior door handle operation. When the latch lever is moved, the door latch releases allowing the
door to open.
Broken or binding linkage

Exterior door handle to latch rod adjustment
Exterior door handle
Door latch
PINPOINT TEST R: A DOOR IS DIFFICULT/DOES NOT OPEN FROM THE EXTERIOR DOOR HANDLE

R1 CHECK THE LATCH OPERATION FROM
BOTH DOOR HANDLES
Yes
Open the door using both the interior and exterior If the door is difficult/does not open from
door handles. only the exterior door handle, GO to R2 .
Does the door open normally from one of the
door handles? No
If the door does not operate correctly from
both door handles, GO to Pinpoint Test Q .
R2 CHECK THE EXTERIOR DOOR HANDLE
Yes
Remove the door trim panel. Refer to Section GO to R3 .
501-05 .
Open the clip and disconnect the exterior door No
handle actuating rod. INSTALL a new exterior door handle.
REFER to Exterior Front Door Handle or
Exterior Rear Door Handle in this section.
Pull and release the exterior door handle.

Does the exterior door handle operate correctly?
R3 CHECK THE EXTERIOR DOOR HANDLE AND
LINKAGE OPERATION
Yes
REPAIR as necessary. TEST the system for

Operate the exterior door handle while observing normal operation.

the linkage.
Are any of the exterior door handle components No
or linkages binding or broken? GO to R4 .
R4 CARRY OUT THE EXTERIOR DOOR HANDLE
ADJUSTMENT
Yes
Carry out the exterior door handle to latch rod The concern was caused by an improperly
adjustment. Refer to Door Handle to Latch Rod adjusted exterior door handle.
Adjustment in this section.
Does the exterior door handle operate correctly? No
INSTALL a new door latch. REFER to
Front Door Latch or Rear Door Latch in this
section. TEST the system for normal
operation.
Pinpoint Test S: A Door Is Difficult/Does Not Open From The Interior Door Handle
Normal Operation
The interior door handle is connected to the door latch by an actuating cable. When the interior door handle is
pulled it causes the cable to pull on the latch lever. When the latch lever is moved, the door latch releases,
allowing the door to open.
Broken or binding cable/linkage

Door latch
PINPOINT TEST S: A DOOR IS DIFFICULT/DOES NOT OPEN FROM THE INTERIOR DOOR HANDLE

S1 CHECK THE LATCH OPERATION
FROM BOTH DOOR HANDLES
Yes
Open the door using both the interior If the door is difficult/does not open from only the
and exterior door handles. interior door handle, GO to S2 .
Does the door open normally from
one of the door handles? No
If the door does not operate correctly from both door
handles, GO to Pinpoint Test Q .
S2 CHECK THE INTERIOR DOOR
HANDLE AND CABLE/LINKAGE
OPERATION
Yes
For the rear doors, make sure that the REPAIR as necessary. TEST the system for normal
child safety lock is off. operation.
Remove the door trim panel. Refer to
Section 501-05 . No
INSTALL a new door latch. REFER to Front Door
PINPOINT TEST R: A DOOR IS DIFFICULT/DOES NOT OPEN FROM THE EXTERIOR DOOR 757
HANDLE
Operate the interior door handle while Latch or Rear Door Latch in this section. TEST the
observing the cable/linkage. system for normal operation.
Are any of the interior door handle
components or cable/linkages
binding or broken?
Pinpoint Test T: Exterior Door Release Handle Sticks
Normal Operation
The exterior door handle is connected to the door latch with an actuating rod. When the exterior door handle is
pulled it causes the actuating rod to push down on the latch lever. The actuating rod can be adjusted for
correct exterior door handle operation. When the latch lever is moved, the door latch releases, allowing the
door to open. The handle has a return spring to make sure the handle returns to a closed position.
Binding linkage
Broken handle return spring
Exterior door handle adjustment
Door latch
PINPOINT TEST T: EXTERIOR DOOR RELEASE HANDLE STICKS

T1 CHECK FOR A BROKEN RETURN
SPRING
Yes
Remove the door trim panel. Refer to Section GO to T2 .
501-05 .
Open the clip and disconnect the exterior No
door handle actuating rod. INSTALL a new exterior door handle. REFER to
Exterior Front Door Handle or Exterior Rear Door
Handle in this section. TEST the system for
normal operation.
Pull and release the exterior door handle.

Does the exterior door handle return to a
closed position once released?
T2 CARRY OUT THE EXTERIOR DOOR
HANDLE ADJUSTMENT
Yes
Carry out the exterior door handle to latch The concern was caused by an improperly
rod adjustment. Refer to Door Handle to adjusted exterior door handle.
Latch Rod Adjustment in this section.
PINPOINT TEST S: A DOOR IS DIFFICULT/DOES NOT OPEN FROM THE INTERIOR DOOR HANDLE
758
Does the exterior door handle operate No

correctly? GO to T3 .
T3 CHECK THE EXTERIOR DOOR HANDLE
AND LINKAGE OPERATION
Yes
Operate the exterior door handle while REPAIR as necessary. TEST the system for
observing the linkage. normal operation.
Are any of the exterior door handle
components or linkages binding? No
INSTALL a new door latch. REFER to Front
Door Latch or Rear Door Latch in this section.
Pinpoint Test U: Interior Door Release Handle Sticks
Normal Operation
The interior door handle is connected to the door latch by an actuating cable. When the interior door handle is
pulled it causes the cable to pull on the latch lever. When the latch lever is moved, the door latch releases,
allowing the door to open. The handle has a return spring to make sure the handle returns to a closed position.
Binding cable
Broken handle return spring
Door latch
PINPOINT TEST U: INTERIOR DOOR RELEASE HANDLE STICKS

U1 CHECK FOR A BROKEN
RETURN SPRING
Yes
Remove the interior door handle. GO to U2 .
Refer to Interior Door Handle in
this section. No
Pull and release the interior door INSTALL a new interior door handle. REFER to Interior
handle. Door Handle in this section. TEST the system for normal
Does the interior door handle operation.
return to a closed position once
released?
U2 CHECK THE INTERIOR DOOR
HANDLE CABLE OPERATION
Yes
Remove the door latch release INSTALL a new door latch. REFER to Front Door Latch or
cable. Rear Door Latch in this section. TEST the system for normal
Observe the door latch release operation.
cable for any damage or binding.
Is the door latch release cable No
OK? REPAIR as necessary. TEST the system for normal operation.
PINPOINT TEST T: EXTERIOR DOOR RELEASE HANDLE STICKS 759

Pinpoint Test V: Squeak/Rattle/Chucking Noise From Door
Door alignment
Striker adjustment
Door latch
PINPOINT TEST V: SQUEAK/RATTLE/CHUCKING NOISE FROM DOOR

V1 CHECK FOR ANY LOOSE
COMPONENTS
Yes
Remove the door trim panel. Refer to REPAIR as necessary. TEST the system for normal
Section 501-05 . operation.
Inspect inside the door for any loose
components. No
Are there any loose components GO to V2 .
inside the door?
V2 CHECK THE STRIKER
ADJUSTMENT
Yes
Check the adjustment of the striker. GO to V3 .
Is the striker adjusted correctly? No
ADJUST the striker as necessary. TEST the system for
normal operation.
V3 CHECK THE DOOR ALIGNMENT
Yes
Check the alignment of the door. GO to V4 .
Is the door aligned correctly? No
ADJUST the door as necessary. TEST the system for
normal operation.
V4 CHECK THE LATCH OPERATION
AFTER LUBRICATION
Yes
Lubricate the door latch. Refer to INSTALL a new door latch. REFER to Front Door Latch
Latch Lubrication in this section. or Rear Door Latch in this section. TEST the system for
Using a screwdriver, fully close the normal operation.
latch (2 clicks).
No
The concern was caused by an insufficiently lubricated
door latch.
PINPOINT TEST U: INTERIOR DOOR RELEASE HANDLE STICKS 760

Operate the door latch and listen for

the noise.
Is the original noise still present
after the latch is lubricated?
Pinpoint Test W: Manual Door Lock Cylinder Inoperative
Normal Operation
The door lock cylinder is connected to the door latch via a lock rod and can be used to manually lock/unlock a
door.
Bent or binding lock rod and lever

Door lock cylinder
Door latch
PINPOINT TEST W: MANUAL DOOR LOCK CYLINDER INOPERATIVE

W1 CHECK THE LOCK
CYLINDER OPERATION AFTER
LUBRICATION
Yes
Spray a lock lubricant such as The concern was caused by an insufficiently lubricated lock
Motorcraft XL-1 into the lock cylinder. Spray a multi-purpose grease such as Motorcraft XL-5
cylinder opening for a couple into the lock cylinder for a couple seconds to provide long term
seconds. lubrication.
Operate the door lock cylinder
with the key. No
Does the door lock and GO to W2 .
unlock using the door lock
cylinder?
W2 CHECK THE DOOR LOCK
CYLINDER
Yes
Remove the door lock cylinder. GO to W3 .
Refer to Door Lock Cylinder in
this section. No
Operate the door lock cylinder INSTALL a new door lock cylinder. REFER to Door Lock
with the key. Cylinder in this section. TEST the system for normal operation.
Does the door lock cylinder
rotate freely to both lock and
PINPOINT TEST V: SQUEAK/RATTLE/CHUCKING NOISE FROM DOOR 761

unlock positions?
W3 CHECK THE DOOR LOCK
CYLINDER LINKAGE
Yes
Operate the door lock cylinder REPAIR as necessary. TEST the system for normal operation.
while observing the linkage.
Is the door lock cylinder rod No
and lever bent or binding? INSTALL a new door latch. REFER to Front Door Latch in this
section. TEST the system for normal operation.
Pinpoint Test X: Ignition Key Cannot Be Returned To The OFF Position
Refer to Wiring Diagrams Cell 37 , Shift Interlock for schematic and connector information.
Normal Operation
On floor shift equipped vehicles, the ignition switch contains a key removal inhibit solenoid. The solenoid
prevents the ignition lock cylinder to be turned to lock and the key removed any time the transmission selector
lever is in any position except park. The inhibit solenoid receives voltage at all times from the Smart Junction
Box (SJB) fuse 27 (27A). When the transmission selector lever is in any gear except park, the selector switch
closes, which supplies ground to the solenoid.
On column shift equipped vehicles, the key removal inhibit is controlled by a mechanical linkage inside the
steering column. The linkage prevents the ignition lock cylinder from being turned to lock and the key
removed any time the transmission selector lever is in any position except park.

Transmission selector lever
Binding steering column components
Ignition lock cylinder
Ignition switch
PINPOINT TEST X: IGNITION KEY CANNOT BE RETURNED TO THE OFF POSITION

X1 CHECK THE SHIFTER TYPE
Yes
Observe the location of the automatic transmission GO to X2 .
shifter.
Is the vehicle equipped with a floor shifter? No
GO to X3 .
X2 CHECK FOR AN ENERGIZED KEY REMOVAL
INHIBIT SOLENOID
Yes
Remove the SJB fuse 27 (20A). REFER to Section 211-05 to continue
Attempt to turn the ignition key to the run position diagnosis of the key removal inhibit
and then back to the lock position and remove the solenoid system.
key.
PINPOINT TEST W: MANUAL DOOR LOCK CYLINDER INOPERATIVE 762

Does the ignition lock cylinder turn to the lock No

position and can the key be removed? GO to X3 .
X3 CHECK THE IGNITION LOCK CYLINDER FOR
BINDING
Remove the ignition lock cylinder. Refer to Ignition

Lock Cylinder - Functional in this section.
Rotate the ignition lock cylinder through all
positions using the key.
Does the ignition lock cylinder freely rotate
through all positions and can the key be removed
from the lock cylinder?
Yes
REFER to Section 211-05 to continue diagnosis of the steering column for any binding steering column
components or ignition switch.
No
INSTALL a new ignition lock cylinder. REFER to Ignition Lock Cylinder - Functional in this section. TEST
PINPOINT TEST X: IGNITION KEY CANNOT BE RETURNED TO THE OFF POSITION 763
SECTION 501-14: Handles, Locks, Latches and Entry 2011 Expedition, Navigator Workshop
Systems Manual
Remote Keyless Entry (RKE) Transmitter Programming
NOTE: This procedure is for programming conventional keyfobs only. The Remote Keyless Entry (RKE)
transmitter of the Integrated Keyhead Transmitter (IKT) is programmed automatically during the Passive
Anti-Theft System (PATS) programming. For additional information, refer to Key Programming Using Two
Programmed Keys or Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment
in Section 419-01B to program the IKT .
NOTE: All RKE transmitters must be programmed at the same time.
NOTE: Do not apply the brake pedal during this sequencing, as doing so ends the sequence and the
transmitters will not be programmed.
1. Electronically unlock the door locks using the door lock control switch.
2. Cycle the ignition switch from the OFF to the RUN position 8 times in rapid succession (within 10
seconds), with the eighth turn ending in RUN. If the module successfully enters program mode, it
locks and then unlocks all the doors.
3. NOTE: If no action is taken within 20 seconds after a transmitter has been programmed, the
programming sequence ends (the doors lock and unlock to confirm that programming is complete).
Within 20 seconds, press any button on the RKE transmitter to be programmed. The doors lock and
then unlock to confirm that each RKE transmitter is programmed. Repeat this step for each RKE
transmitter.
4. Exiting the programming mode is accomplished if one of the following occurs:

The key transitions to the OFF position.
20 seconds have passed since entering programming mode or since the last RKE transmitter
was programmed.
The maximum number (4) of RKE transmitters have been programmed.
5. Check the operation of the RKE transmitter. If the door locks do not respond for the programmed
RKE transmitter(s), wait several seconds and press the button again. If the door locks still fail to
respond, refer to Handles, Locks, Latches and Entry Systems in this section. (Make sure that no more
than the maximum number of RKE transmitters are attempted to be programmed.)
Remote Keyless Entry (RKE) Transmitter Programming 764

Remote Keyless Entry (RKE) Transmitter Programming 765

Systems Manual
Keyless Entry Keypad Code Programming
Programming a Personal Entry Code and Keypad Association to Memory Features (If Equipped)
NOTE: The system allows 3 personal codes to be programmed.
NOTE: Multiple personal codes can be programmed in one step. When programming multiple codes in one
step, each code must be programmed by entering each button within 5 seconds of each other. If 5 seconds
elapse between any button press, programming mode is exited.
NOTE: If only a single personal code is desired or unable to program multiple codes in one step, each
personal code can be programmed individually by repeating Steps 1-5 for each code desired.
1. Enter the factory set 5-digit keyless entry keypad code.
2. Within 5 seconds, press the 1/2 button on the keypad to activate the programming mode.
3. Enter the new personal 5-digit keyless entry keypad code. Each number must be entered within 5
seconds of each other.
4. After entering the new personal code, press a 6th button to program each new code.
Pressing 1/2 stores the first personal code (if equipped with memory, this code is associated
with driver 1 settings).
Pressing 3/4 stores the second personal code (if equipped with memory, this code is
associated with driver 2 settings).
Pressing 5/6, 7/8 or 9/0 stores the third personal code, but does not associate the code with a
memory setting.
5. The door locks lock and unlock to confirm the new code is programmed.
Erasing a Personal Entry Code
1. Enter the factory set 5-digit keyless entry keypad code.
2. Within 5 seconds, press the 1/2 button on the keypad and release.
3. Within 5 seconds, press and hold the 1/2 button for 2 seconds.
4. All personal codes are now erased and only the factory set 5-digit code works.
Keyless Entry Keypad Code Programming 766

Keyless Entry Keypad Code Programming 767

Systems Manual
Remote Memory Activation
1. Position the driver seat, adjustable pedals, steering column and exterior mirror to the desired
positions.
2. Press and hold either memory button (1 or 2) for 5 seconds. A tone is heard after 1-1/2 seconds when
the memory store is done. Continue to hold until a second tone is heard after 5 seconds.
3. Within 3 seconds, press the LOCK button on the Remote Keyless Entry (RKE) transmitter.
4. If a second memory setting is desired, repeat the procedure with the second RKE transmitter.
Remote Memory Activation 768

Systems Manual
Remote Memory Deactivation
1. Press and hold either memory button (1 or 2) for 5 seconds. A tone is heard after 1-1/2 seconds when
the memory store is done. Continue to hold until a second tone is heard after 5 seconds.
2. Within 3 seconds, press the UNLOCK button on the Remote Keyless Entry (RKE) transmitter.
3. If a second memory setting is desired to be deactivated, repeat the procedure with the second RKE
transmitter.
Remote Memory Deactivation 769

Systems Manual
Autolock and Auto-Unlock Programming
Programming the Autolock Feature Using the Door Lock Control Switch
NOTE: This feature can also be enabled or disabled using the message center switch functions, if equipped.
NOTE: The autolock feature can be enabled or disabled independently of the auto-unlock feature.
NOTE: The following steps must be carried out within 30 seconds or the procedure needs to be repeated. If
the procedure needs to be repeated, wait 30 seconds between programming sessions.
1. Turn the ignition switch from the OFF to the RUN position.
2. Press the unlock button on the door lock control switch 3 times.
3. Turn the ignition switch from the RUN to the OFF position.
5. Turn the ignition switch to the RUN position. The horn chirps once to indicate that programming
mode is entered.
6. NOTE: The unlock and lock buttons must be pressed within 5 seconds of each other.
Within 30 seconds of entering the programming mode, press the unlock button and then the lock
button on the door lock control switch within 5 seconds to enable/disable the autolock feature. The
horn chirps once if the autolocks are disabled or a chirp followed by a honk if the autolocks are
enabled.
7. Programming ends when the ignition switch state changes or times out after 2 minutes.
Programming the Auto-Unlock Feature Using the Door Lock Control Switch
NOTE: This feature can also be enabled or disabled using the message center switch functions, if equipped.
NOTE: The auto-unlock feature can be enabled or disabled independently of the autolock feature.
1. Turn the ignition switch from the OFF to the RUN position.
3. Turn the ignition switch from the RUN to the OFF position.
5. Turn the ignition switch to the RUN position. The horn chirps once to indicate that programming
mode is entered.
Autolock and Auto-Unlock Programming 770

6. NOTE: The lock and unlock buttons must be pressed within 5 seconds of each other.
Within 30 seconds of entering the programming mode, press the lock button on the door lock control
switch then the unlock button to enable/disable the auto-unlock feature. The horn chirps once if the
autolocks are disabled or a chirp followed by a honk if the autolocks are enabled.
7. Programming ends when the ignition switch state changes or times out after 2 minutes.
Programming the Autolock Feature Using the Keyless Entry Keypad
NOTE: The autolock feature can be enabled or disabled independently of the auto-unlock feature.
1. Enter the factory set 5 digit entry code.
2. Press and hold the 3/4 button.
3. While holding the 3/4 button, press and release the 7/8 button.
4. Release the 3/4 button. The horn chirps once if the autolocks are disabled, or chirps once followed by
a honk if the autolocks are enabled.
Programming the Auto-Unlock Feature Using the Keyless Entry Keypad
NOTE: The auto-unlock feature can be enabled or disabled independently of the autolock feature.
1. Enter the factory set 5 digit entry code.
2. Press and hold the 3/4 button.
3. While holding the 3/4 button, press and release the 7/8 button twice.
4. Release the 3/4 button. The horn chirps once if auto-unlock is disabled, or chirps once followed by a
honk if auto-unlock is enabled.


Systems Manual
Stepped Unlock Programming
1. With the ignition switch in the OFF position, press the LOCK and UNLOCK buttons on the Remote
Keyless Entry (RKE) transmitter simultaneously for 4 seconds.
The turn signals flash twice to indicate the mode change.
2. Repeat Step 1 to enable/disable the stepped unlocking feature.
Stepped Unlock Programming 773

Systems Manual
Liftgate Latch Manual Release
1. Remove the liftgate latch access cover from the center of the liftgate trim panel.
2. Vehicles with manual liftgate, press the liftgate latch manual release lever to the left to release the
liftgate latch.
3. Vehicles with power liftgate, press the liftgate latch manual release lever down to release the liftgate
latch.
Liftgate Latch Manual Release 774

Systems Manual
Door Handle to Latch Rod Adjustment
NOTE: If the vehicle is equipped with an adjustable door latch actuating rod, perform this procedure.
NOTE: An incorrectly adjusted exterior door handle can cause a loose handle, rattle noise, door hard to open
from the outside door handle, or the outside door handle to not sit flush in the closed position.
NOTE: Prior to carrying out the adjustment procedure, the door latch, exterior door handle, and linkages must
be installed on the door.
1. Raise the door glass to the full-up position.
2. Remove the door trim panel. For additional information, refer to Section 501-05 .
3. Position the water shield aside.
4. Open the clip and disconnect the exterior door handle actuating rod.
5. Position the actuating rod and latch actuating lever in a neutral position.
6. NOTE: Do not push up or pull down on the actuating rod or latch actuating lever.
Reinstall the exterior door handle actuating rod back into the clip.
7. Close the clip and test the system to make sure that the exterior door handle is operating correctly.
8. Reseal the water shield.
9. Install the door trim panel. For additional information, refer to Section 501-05 .
Door Handle to Latch Rod Adjustment 775

Door Handle to Latch Rod Adjustment 776

Systems Manual
Latch Lubrication
Material
Item Specification
XG-4 and/or XL-5
1. Open the door.
2. Using a screwdriver, fully close the latch (2 clicks).
3. Spray the multi-purpose grease into the opening on the door latch for approximately 5 seconds.
4. Open the latch using either the interior or exterior door handle.
5. Open and close the door several times to circulate the lubricant inside the latch.
6. Wipe off any excess grease.
Latch Lubrication 777

Latch Lubrication 778


Workshop Manual
Hood Latch

1 N804837 Upper radiator sight shield pin-type retainers (10
required)
2 19E525 Upper radiator sight shield
3 W711848 Hood latch bolts (2 required)
4 16700 Hood latch
5 - Hood latch cable (part of 16916)
6 N807014 Hood striker bolts (2 required)
7 16K689 Hood striker
1. Remove the 10 pin-type retainers and the upper radiator sight shield.
2. Remove the 2 bolts and the hood latch.

3. Release the hood latch cable from the hood latch.

Verify the hood latch engages the striker in the latched position (secondary).
Verify the hood latch engages the striker in the fully latched position (primary).
Adjust the hood latch as necessary.
Hood Latch 779

Hood Latch 780


Workshop Manual
Hood Latch Release Handle

1 W707628 Steering column cover screws (3 required)
2 7804459 Steering column cover
3 W707628 Hood latch release handle screws (2 required)
4 16916 Hood latch release handle
1. Remove the hood latch. For additional information, refer to Hood Latch in this section.
Note the routing of the hood latch release cable.
2. Remove the 3 screws and the steering column cover.
3. Remove the 2 screws and the hood latch release handle.
4. Release the cable guides and pull the cable through the cowl panel.
Hood Latch Release Handle 781

Hood Latch Release Handle 782


Workshop Manual
Interior Door Handle
NOTE: Door trim panel removed for clarity.

1 7821819/ Interior door handle (LH/RH)
7821818
2 - Interior door handle actuating cable (part of the
latch)
1. Remove the screw and the interior door handle trim bezel.
2. Release the door handle retaining clip and position the interior door handle aside.
3. Release the interior door handle actuating cable from the interior door handle.
4. NOTE: Make sure the interior door handle spring is realigned before installation of the door handle.
Check for normal operation.
Interior Door Handle 783

Interior Door Handle 784


Workshop Manual
Front Door Latch

1 W705830 Front door latch bolts (3 required)
2 7822135 Door lock cylinder actuating lock rod
3 7822853/ 7822852 Front door manual actuating lock rod (LH/RH)
4 1621813/ 1621812 Front door latch (LH/RH)
5 W714070 Front door striker bolts (2 required)
6 5422008 Front door striker
NOTE: The front door window glass must be completely raised.
Position the water shield aside.
2. For the LH door, disconnect the door lock cylinder actuating lock rod from the lock cylinder.
Front Door Latch 785

4. Disconnect the manual actuating lock rod from the door latch.
5. Remove and discard the 3 bolts and position the front door latch aside.

Separate the door harness from the door latch.
7. Release the interior door handle actuating cable and remove the front door latch.
1. Position the cable cover aside.
2. Release the conduit and the interior door handle actuating cable.
8. NOTE: Make sure the exterior door handle and the door handle actuating rod are in a neutral position
and that the exterior door handle rod is all the way up before closing the clip.



Workshop Manual
Exterior Front Door Handle

1 7822153/ 7822152 Exterior door handle actuating rod (LH/RH)
2 - Exterior door handle nuts (2 required)
3 7822405/ 7822404 Exterior door handle (LH/RH)
NOTE: The front door window glass must be completely raised.
3. If equipped, disconnect the door lock cylinder actuating rod from the lock cylinder.
4. NOTE: Push the exterior door handle out from the bottom surface of the handle.
Remove the 2 nuts and the exterior front door handle.
Exterior Front Door Handle 788

5. NOTE: Make sure the exterr door handle and the door handle actuating rod are in a relaxed position
Exterior Front Door Handle 789


Workshop Manual
Rear Door Latch

1 W705830 Rear door latch bolts (3 required)
2 - Exterior door handle actuating rod
3 1626413/ 1626412 Rear door latch (LH/RH)
4 W714070 Rear door striker bolts (2 required)
5 5422008 Rear door striker
NOTE: The rear door window glass must be completely raised.
1. Remove rear door trim panel. For additional information, refer to Section 501-05 .
2. Remove and discard the 3 bolts and position the rear door latch aside.
Rear Door Latch 790

5. Position the cable cover aside.
2. Release the conduit and the interior door handle actuating cable.
6. NOTE: Make sure the exterior door handle and the door handle actuating rod are in a neutral position
Rear Door Latch 791


Workshop Manual
Exterior Rear Door Handle

1 - Exterior door handle actuating rod
2 W705760 Exterior door handle nuts (2 required)
3 7826605/ 7826604 Exterior door handle (LH/RH)
NOTE: The door glass must be completely raised.
2. Remove and discard the 3 bolts and position the rear door latch aside.
4. Remove the 2 nuts and the exterior rear door handle.

5. NOTE: Make sure the exterior door handle and the door handle actuating rod are in a relaxed position
Exterior Rear Door Handle 792

>
Exterior Rear Door Handle 793


Workshop Manual
Liftgate Latch
Manual Liftgate

1 N807675 Liftgate latch bolts (3 required)
2 - Liftgate latch electrical connector (part of 14086)
3 7843150 Liftgate latch
4 W714070 Liftgate striker bolts (2 required)
5 7843252 Liftgate striker
Power Liftgate

1 N807675 Liftgate latch bolts (4 required)
2 - Liftgate latch electrical connector (part of 14086)
3 7843150 Liftgate latch
Liftgate Latch 794

4 W714070 Liftgate striker bolts (2 required)

5 7843252 Liftgate striker
1. Remove the liftgate trim panel. For additional information, refer to Section 501-05 .
2. Remove and discard the 3 bolts (4 bolts if equipped with a power liftgate) and the liftgate latch.
Power Liftgate 795


Workshop Manual
Liftgate Latch - Window

1 78421A00 Liftgate glass latch screws (2 required)
2 - Liftgate glass latch electrical connector (part of 14086)
3 7840860 Liftgate glass latch
4 - Liftgate glass striker
2. Remove the 2 screws and the liftgate window latch.

Liftgate Latch - Window 796

Liftgate Latch - Window 797


Workshop Manual
Liftgate Release Switch
Expedition

1 14018 Liftgate release switch
2 7843400 Liftgate handle
3 N621906 Liftgate handle nuts (2 required)
Navigator

1 14018 Liftgate release switch
2 7843400 Liftgate release switch housing
3 78404C42 License plate housing
4 N621906 Liftgate release switch housing nuts (2 required)
5 N621906 License plate housing nuts (6 required)
Liftgate Release Switch 798

All vehicles
Expedition
2. Remove the 2 nuts and the liftgate release handle.

3. Remove the liftgate release switch.

Navigator
4. Remove the liftgate parking lamps. For additional information, refer to Section 417-01 .
5. Remove the 6 nuts and the license plate housing.

6. Remove the 2 nuts and the liftgate release switch housing.

7. Remove the liftgate release switch.

All vehicles
Navigator 799

Workshop Manual
Door Lock Actuator

1 - Door latch
2 25218A43/ 25218A42 Door lock actuator (LH/RH)
1. Remove the door latch. For additional information, refer to Front Door Latch or Rear Door Latch in
this section.
2. Release the locking tab and remove the door lock actuator.
Door Lock Actuator 800


Workshop Manual
Door Ajar Switch
NOTE: LH front door latch shown, others similar.

1 - Door latch
2 13713/14018 Door ajar switch (LH/RH)
1. Remove the door latch. For additional information, refer to Front Door Latch or Rear Door Latch in
this section.
2. Release the locking tab and remove the door ajar switch.
Door Ajar Switch 801

Door Ajar Switch 802


Workshop Manual
Door Lock Cylinder

1 7822405 Exterior door handle
2 1222023 Door lock cylinder retainer
3 7821990 Door lock cylinder
NOTE: Individual lock cylinders are repaired by discarding the inoperative lock cylinder and building a new
lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed
instruction sheet to build the new lock cylinder to the current code of the vehicle.
1. Remove the exterior front door handle. For additional information, refer to Exterior Front Door
Handle in this section.
2. Remove the retainer and the front door lock cylinder.
Door Lock Cylinder 803

Door Lock Cylinder 804


Workshop Manual
Ignition Lock Cylinder - Functional

1 - Ignition lock cylinder housing (part of 3L529)
2 11582 Ignition lock cylinder
Removal
NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock
cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction
sheet to build the new lock cylinder to the current key code of the vehicle.
1. Remove the Passive Anti-Theft System (PATS) transceiver. For additional information, refer to
Section 419-01B .
2. Insert the ignition key and position the ignition lock cylinder to the ACC position.
3. Using a suitable tool, depress the ignition lock cylinder release pin through the access hole while
pulling the ignition lock cylinder outward.
Installation
1. Make sure the ignition lock cylinder is in the ACC position.
2. Insert the ignition lock cylinder into the ignition lock cylinder access hole located on the steering
column.
Make sure to align the locking pin with the locking pin access hole.
3. Install the Passive Anti-Theft System (PATS) transceiver. For additional information, refer to Section
419-01B .
4. Rotate the ignition key through all lock cylinder positions to check for correct operation.
Ignition Lock Cylinder - Functional 805

Ignition Lock Cylinder - Functional 806


Workshop Manual
Ignition Lock Cylinder - Non Functional
Removal
1. Remove the Passive Anti-Theft System (PATS) transceiver. For additional information, refer to
Section 419-01B .
2. Remove the ignition lock cylinder.

Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
Use a 3/8-inch diameter drill bit to drill down the middle of the ignition lock key slot until the
ignition lock cylinder breaks loose.
Remove and discard the ignition lock cylinder and drill shavings from the steering column.
3. Remove the bearing retainer.
4. Remove the steering column lock housing bearing and steering column lock gear.
Installation
1. Thoroughly clean all drill shavings from the steering column and inspect it for damage.
2. Install a new ignition lock cylinder.

Verify the ignition lock cylinder operation.
3. Program the new PATS keys. For additional information, refer to Integrated Keyhead Transmitter
(IKT) Key Programming Using Diagnostic Equipment in Section 419-01B .
Ignition Lock Cylinder - Non Functional 807


Workshop Manual

1 7821453 Front door outer glass weatherstrip
2 14A626 Keyless entry keypad
1. Remove the exterior mirror. For additional information, refer to Section 501-09 .
2. Remove the front door outer glass weatherstrip.

3. Release the tabs and remove the keyless entry keypad.

Disconnect the keypad harness retaining clips from the weatherstrip.
Keyless Entry Keypad 808


SECTION 501-16: Wipers and Washers 2011 Expedition, Navigator Workshop Manual
Material

Capacity
Motorcraft Premium Quality - -
Windshield Washer Fluid
(Canada)
CXC-37-(A, B, D, and F)
(Canada)
Motorcraft Premium Windshield WSB-M8B16-A2 -
Washer Concentrate (US)
ZC-32-A or B (US)
Item Specification
LH windshield wiper blade park measurement 50-70 mm (2.0-2.9 in)
Rear window wiper blade park measurement 60-80 mm (2.4-3.2 in)
RH windshield wiper blade park measurement 50-70 mm (2.0-2.9 in)

Liftgate window glass latch bolts 8 - 71
Rear window glass handle nut 18 - 159
Rear window striker and wiper pivot shaft assembly nuts 6 - 53
Rear window wiper motor bolts 11 - 97
Rear window wiper pivot arm nut 12 - 106
Windshield wiper motor bolts 15 - 133
Windshield wiper motor crank nut 29 21 -
Windshield wiper mounting arm and pivot shaft bolts 8 - 71
Windshield wiper pivot arm nuts 35 26 -


Wipers and Washers
The wiper and washer system consists of the following components:
Front windshield wiper motor

Multifunction switch
Rear window wiper blade
Rear window wiper motor
Rear window wiper pivot arm
Rear window wiper striker and wiper pivot shaft assembly
Windshield (2-way) washer fluid pump
Windshield washer fluid reservoir (integral to the battery tray)
Windshield wiper mounting arm and pivot shaft
Windshield wiper pivot arms
NOTE: The Smart Junction Box (SJB) may also be identified as the Generic Electronic Module
(GEM).
SJB
Rain sensor (if equipped)
Rain sensor bracket (if equipped)
Wipers
The wiper system is activated by the multifunction switch. The multifunction switch provides input to the
front wiper motor module to activate wash, low, high and intermittent modes. Intermittent settings are
replaced by sensitivity settings on vehicles equipped with rain sensitive wipers. The multifunction switch also
provides input to the rear wiper module to activate wash, INT 1 and INT 2 modes. The wiper motor contains
relays that are not serviceable separately. If equipped with automatic headlamps, the SJB will illuminate the
exterior lamps within 10 seconds, when the front wipers are active and the headlamp control switch is in the
AUTOLAMP position. When the wipers are turned off, the exterior lamps will remain on for 30 seconds
before turning off.
Washers
The front and rear washer system share the same washer reservoir and washer pump. The washer reservoir is
integral to the battery tray. Refer to Section 414-01 . The front and rear wiper motor integral electronics
control the direction of the washer pump to direct washer fluid to the windshield or rear window. When the
washer system is activated, the wipers will cycle 2-3 times with washer fluid, followed by one final wipe a
few seconds later to clear any remaining fluid that is dripping down from the top of the windshield.
Rain Sensitive Wipers (if equipped)
When equipped, the rain sensitive wipers feature replaces the standard intermittent wiper feature. The
multifunction switch must be positioned to any of the 5 auto/intermittent settings to activate the rain sensitive
wipers. The lowest setting (closest to OFF) is the least sensitive to moisture. The highest setting is the most
sensitive to moisture. The windshield wipers cycle when the multifunction switch is placed into or changing
between the auto/intermittent settings. When the rain sensitive wiper feature is active, the system adjusts the
wiper speed automatically when moisture is detected on the windshield.
A lens/bracket service kit is available to repair/replace a detached bracket or a damaged/contaminated gel-type

lens. The rain sensor gel-type lens cannot be reused on a rain sensor of this type. When reinstalling a rain
sensor, a new lens from the lens/bracket service kit must be installed to the rain sensor. Refer to Rain Sensor .
Wipers and Washers 812

Rain Sensitive Wipers (if equipped) 813

Wipers and Washers
Special Tool(s)
Flex Probe Kit



Wipers and Washers
The windshield wiper system consists of an integrated wiper motor and module assembly, which contains
internal washer, run/park and high/low speed relays. The windshield wiper motor and module assembly also
contains a Hall-effect sensor that is used to determine the parked position of the wiper motor during a cycle.
The integrated windshield wiper motor and module assembly has different operating modes: OFF, LOW
speed, HIGH speed, MIST, WASH INTERMITTENT, SOFTWARE SAFE mode and if equipped, automatic
wiping.
High-Speed Wipers
When the multifunction switch is set to the HIGH-speed position, it supplies ground to the high/low speed
relay coil and the run/park relay coil, which causes the windshield wiper motor to operate at high speed.
During high-speed operation only, both the high/low-speed relay coil ground and the run/park relay coil
ground are controlled directly by the multifunction switch. This differs from LOW speed or intermittent
operation when the run/park relay coil is controlled by the microprocessor. When the switch is placed in the
OFF position, the motor continues to operate until the motor returns to the PARK position and the internal
Hall-effect sensor senses the motor magnet. The output to the run/park relay deactivates the relay and
disconnects the voltage to the motor.
Since the high/low relay coil and the run/park relay coil are both controlled by a hard-wired circuit to the
multifunction switch, the windshield wipers will still operate in high-speed mode if the internal windshield
wiper module fails, but will not automatically park when the multifunction switch is turned to the OFF
position.
Low-Speed Wipers
When the multifunction switch is set to the LOW-speed position, it supplies ground to the internal wiper
motor module low-speed inputs and the wiper motor operates at low speed. During low-speed operation, the

internal run/park relay is activated by the microprocessor and supplies 12 volts to the low-speed brush of the
wiper motor. The run/park relay coil ground is controlled by the internal wiper motor module based on inputs
received from the multifunction switch. When the switch is placed in the OFF position, the motor continues to
operate until the motor returns to the PARK position and the internal Hall-effect sensor senses the motor
magnet. The output to the run/park relay deactivates the relay and disconnects the voltage to the motor.
Intermittent Wipers
When the multifunction switch is set to the intermittent position(s), it supplies ground to the wiper motor
module inputs and the wiper motor operates in intermittent mode. During intermittent operation, the wiper
motor activates the run/park relay coil which sends voltage through the high/low relay. The high/low relay
remains deactivated, supplying the voltage to the low-speed brush of the wiper motor. The wiper motor
continues to operate until the internal Hall-effect sensor senses the magnet (PARK position) and deactivates
the run/park relay, which disconnects voltage from the wiper motor. The windshield wipers remain parked
until the wiper motor module completes a time-out and then repeats the intermittent wiper cycle.
Wiper Activated Headlamps (if equipped with Autolamp System)
The SJB sends a voltage signal to the wiper motor module in order to monitor the status of the wipers. When
the headlamp control switch is in the AUTOLAMP position, the SJB will activate the headlamps within 10
seconds of the wipers being activated. When the SJB detects that the wipers have been turned off, the SJB will
turn off the headlamps after 30 seconds.
Rain Sensitive Wipers (if equipped)
The rain sensitive feature replaces the intermittent wiper feature. When the rain sensitive wiper system is
active, the rain sensor sends data to the wiper motor. The wipers activate based on the amount of moisture
detected on the windshield and the setting on the multifunction switch.
The rain sensor optically senses water on the windshield. An infrared beam lights a section of the windshield.
The intensity of the reflected beam is measured and compared to the intensity of the transmitted beam. If there
is water on the surface of the windshield, the beam distorts, reducing the intensity of the beam. If the beam is
not reflected completely, it is interpreted as rain on the windshield and the windshield wipers are activated.
If a fault is detected with the rain sensor input by the windshield wiper motor, the wiper motor switches to a
default intermittent mode. The timing of the wipers correspond to a standard intermittent setting based on the
selection on the multifunction switch.
A gel-type lens is used as the interface between the rain sensor and the windshield. If the lens is missing or
damaged, the rain sensing wipers may be inoperative. If the rain sensitive wipers are inoperative and do not
default to the intermittent mode, inspect the rain sensor and confirm that the gel-type lens over the rain sensor
is undamaged.
Washer
The front and rear washer system use the same washer reservoir/battery tray and washer pump. The front and
rear wiper motor modules each contain an integral washer relay. When the windshield and rear window
washer relays are inactive, the washer relays supply a path to ground to the washer motor.
When the windshield wiper motor module receives a windshield wash signal from the multifunction switch,
the windshield wiper motor module activates its integral windshield washer relay which sends voltage to the
washer pump. The washer pump receives ground from the inactive rear window washer relay in the rear wiper
motor module.

When the rear wiper motor module receives a rear window wash signal from the multifunction switch, the rear
wiper motor module activates its integral rear window washer relay which sends voltage to the washer pump.
The washer pump receives ground from the windshield washer relay in the windshield wiper motor module.
Software Safe Mode
The windshield wiper motor defaults to software safe mode when the run/park sensor does not sense the
Hall-effect magnet inside the wiper motor. This can be caused by an obstruction of the windshield wipers, a
binding linkage or loss of the Hall-effect signal. The motor continues to operate in a high/low speed condition,
and when turned off, the wipers immediately park on the windshield. If necessary, the wipers can be turned on
and off until they return to the PARK position.
Windshield Wiper Circuit Function Table
Circuit
Multifunction CRW07 Circuit CRW08 Circuit CRW19 Circuit CRW18 Circuit CRW17
Switch Position (GY/BN) (VT/OG) (BU/OG) (VT/WH) (GN/VT)
OFF OPEN OPEN OPEN OPEN OPEN
INT 1 OPEN OPEN OPEN OPEN GROUND
INT 2 OPEN OPEN OPEN GROUND GROUND
INT 3 OPEN OPEN OPEN GROUND OPEN
INT 4 OPEN OPEN GROUND GROUND OPEN
INT 5 OPEN OPEN GROUND OPEN OPEN
LOW OPEN OPEN GROUND OPEN GROUND
HIGH OPEN GROUND GROUND OPEN GROUND
WASH GROUND OPEN/GROUND OPEN/GROUND OPEN/GROUND OPEN/GROUND
Rear Wiper Circuit Function Table
Multifunction Switch Position Circuit CRW21 (YE/VT) Circuit CRW20 (GY/YE)

OFF OPEN OPEN
INT 1 OPEN GROUND
INT 2 GROUND GROUND
WASH GROUND OPEN
1. Verify the customer concern by operating the system.
2. Visually inspect the following for obvious signs of mechanical or electrical damage.

Windshield washer Battery Junction Box (BJB) fuse 50

hoses (30A)
Washer nozzles Smart Junction Box (SJB) fuses:
Wiper linkage 19 (25A)
Wiper blades 43 (10A)
Washer reservoir 45 (5A)
Wiper pivot shaft Multifunction switch
mounting Wiper motor
Washer pump
Rain sensor
BJB
SJB
Wiring harness
4. NOTE: The windshield wiper motor does not communicate on the network. The windshield wiper
motor provides wiper on/off status directly to the SJB . The windshield wiper motor receives Vehicle
Speed Sensor (VSS) directly from the PCM.
NOTE: Make sure to use the latest scan tool software release.


refer to Section 418-00 to diagnose no response from the SJB or PCM.

If the scan tool responds with no communication from one or more modules, refer to Section
418-00 .
If the network test passes, retrieve and record the Continuous Memory Diagnostic Trouble
Codes (CMDTCs).

8. Clear the continuous DTCs and carry out the self-test diagnostics for the SJB and PCM.
9. If the DTCs retrieved are related to the concern, go to the Smart Junction Box (SJB) DTC Chart or the
Powertrain Control/Emissions Diagnosis (PC/ED) manual for PCM related DTCs. For all other DTCs,
refer to Section 419-10 .
DTC Chart

B2008 Wipers On Signal Circuit Short to Ground GO to Pinpoint Test J .
All Other DTCs - REFER to the Master DTC Chart in Section
419-10 .
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test A: The Wipers are Inoperative - Windshield
Refer to Wiring Diagrams Cell 81 , Wipers and Washers for schematic and connector information.
Normal Operation
When the ignition switch is in the RUN or ACCESSORY position, voltage is supplied to the front wiper relay
coil through circuit CBP45 (YE). The front wiper relay coil is grounded at all times throughcuit GD123
(BK/GY). Voltage is supplied to the front wiper relay through circuit CRW03 (VT/WH). The wiper motor is
grounded through circuits GD133 (BK) and GD120 (BK/GN). The multifunction switch is grounded through
circuit GD138 (BK/WH). The multifunction switch sends open and ground input signals to the wiper motor
through circuits CRW17 (GN/VT), CRW18 (VT/WH), CRW19 (BU/OG) and CRW08 (VT/OG) in order to
activate the wiper motor to the requested modes.

Fuse(s)
Front wiper relay
Wiper motor

PINPOINT TEST A: THE WIPERS ARE INOPERATIVE - WINDSHIELD

A1 CHECK CIRCUIT CRW03 (VT/WH) FOR
VOLTAGE
Yes
Disconnect: Wiper Motor C125. GO to A6 .
Ignition ON.
Measure the voltage between ground and wiper No
motor: GO to A2 .
C125-5, circuit CRW03 (VT/WH),
harness side.
harness side.

A2 CHECK THE FRONT WIPER RELAY
Yes
Disconnect: Front Wiper Relay.
Carry out the Relay component test for the front No
wiper relay. INSTALL a new front wiper relay. TEST the
Refer to Wiring Diagrams Cell 149 for component
testing.
Did the front wiper relay pass the component
test?
A3 CHECK CIRCUIT CBP45 (YE) FOR VOLTAGE
Yes
Measure the voltage between front wiper relay
socket pin 1, circuit CBP45 (YE) and ground. No
VERIFY Smart Junction Box (SJB) fuse 45
(5A) is OK. If OK, REPAIR the circuit.

circuit short. REPAIR the circuit. TEST the
PINPOINT TEST A: THE WIPERS ARE INOPERATIVE - WINDSHIELD 819


A4 CHECK CIRCUIT SBB50 (YE/RD) FOR
VOLTAGE
Yes
Measure the voltage between front wiper relay GO to A5 .
socket pin 3, circuit SBB50 (YE/RD) and ground.
No
VERIFY Battery Junction Box (BJB) fuse 50
(30A) is OK. If OK, REPAIR the circuit.

circuit short. REPAIR the circuit. TEST the

A5 CHECK CIRCUIT GD123 (BK/GY) FOR
GROUND
Yes
Measure the resistance between front wiper relay REPAIR open in circuit CRW03 (VT/WH).
socket pin 2, circuit GD123 (BK/GY) and ground. TEST the system for normal operation.
No
REPAIR open in circuit GD123 (BK/GY).


A6 CHECK CIRCUITS GD120 (BK/GN) AND
GD133 (BK) FOR AN OPEN
Yes
Measure the resistance between ground and wiper
motor: No
C125-6, circuit GD120 (BK/GN), harness REPAIR the circuit(s). TEST the system for
C125-3, circuit GD133 (BK), harness
side.

A7 CHECK THE MULTIFUNCTION SWITCH
Yes
Disconnect: Multifunction Switch C202. GO to A8 .
Carry out the Multifunction Switch component
test. No
INSTALL a new multifunction switch.
Refer to Wiring Diagrams Cell 149 for component REFER to Section 211-05 .
testing.
Did the multifunction switch pass the
component test?
A8 CHECK CIRCUIT GD138 (BK/WH) FOR AN
OPEN
Yes
Measure the resistance between multifunction GO to A9 .
switch C202-15, circuit GD138 (BK/WH), harness
side and ground. No
normal operation.


A9 CHECK FOR CORRECT WIPER MOTOR
OPERATION
Yes
Disconnect all wiper motor connectors. INSTALL a new wiper motor. REFER to
Check for: Wiper Motor - Windshield in this section.
corrosion.
pushed-out pins. No
Connect all the wiper motor connectors and make The system is operating correctly at this
sure they seat correctly. time. Concern may have been caused by a
Operate the system and verify the concern is still loose or corroded connector. TEST the
present. system for normal operation.
Pinpoint Test B: The Wipers are Inoperative - Rear Window
Normal Operation
During normal operation, the rear wiper motor receives voltage at all times through Smart Junction Box (SJB)
fuse 19 (25A), circuit SBP19 (BU/RD). The rear wiper motor also receives power with the ignition switch in
RUN or ACC positions through SJB fuse 43 (10A), circuit CBP43 (GY). Ground is provided to the
windshield wiper motor through circuit GD150 (BK/WH). The rear window wiper motor receives open and
ground inputs from the multifunction switch through circuits CRW20 (GY/YE) and CRW21 (YE/VT) to
activate the wiper to the appropriate modes. The multifunction switchplies a ground input to the rear wiper
motor on circuit CRW21 (YE/VT) when INT 1 is selected. The multifunction switch supplies ground to the
rear wiper motor on circuits CRW21 (YE/VT) and CRW20 (GY/YE) when INT 2 is selected.

Fuse(s)
PINPOINT TEST B: THE WIPERS ARE INOPERATIVE - REAR WINDOW

B1 CHECK CIRCUITS CBP43 (GY) AND SBP19
(BU/RD) FOR VOLTAGE

Ignition OFF. Yes

Disconnect: Rear Wiper Motor C476. GO to B2 .
Ignition ON.
Measure the voltage between rear wiper motor No
C476-7, circuit CBP43 (GY), harness side and VERIFY SJB fuses 43 (10A) and 19 (25A)
ground; and between rear wiper motor C476-8, are OK. If OK, REPAIR the circuit(s) in
circuit SBP19 (BU/RD), harness side and ground. question. TEST the system for normal
operation.

manual to identify the possible causes of
the circuit short. REPAIR the circuit.

B2 CHECK CIRCUIT GD150 (BK/WH) FOR AN
OPEN
Yes
Measure the resistance between rear wiper C476-2,
circuit GD150 (BK/WH), harness side and ground. No
REPAIR the circuit(s) in question. TEST

B3 CHECK THE MULTIFUNCTION SWITCH
Yes
Disconnect: Multifunction Switch C202.
Carry out the Multifunction Switch component test. No
testing.
Did the multifunction switch pass the component
test?
B4 CHECK CIRCUIT GD138 (BK/WH) FOR AN
OPEN
Yes
Measure the resistance between C202-15, circuit GO to B5 .
GD138 (BK/WH), harness side and ground.
No
normal operation.
PINPOINT TEST B: THE WIPERS ARE INOPERATIVE - REAR WINDOW 823


B5 CHECK CIRCUIT CPL80 (WH/GN) FOR AN
OPEN
Yes
The liftgate glass must be closed. GO to B6 .
Measure the resistance between C476-6, circuit
CPL80 (WH/GN), harness side and ground. No
normal operation.

B6 CHECK CIRCUIT CRW21 (YE/VT) FOR AN
OPEN
Yes
Measure the resistance between multifunction switch GO to B7 .
C202-13, circuit CRW21 (YE/VT), harness side and
rear window wiper C476-1, circuit CRW21 No
(YE/VT), harness side. REPAIR the circuit. TEST the system for
normal operation.

B7 CHECK FOR CORRECT WIPER MOTOR
OPERATION
Yes
Disconnect all wiper motor connectors. INSTALL a new rear window wiper
Check for: motor. REFER to Wiper Motor - Rear
liftgate glass open. Window in this section.
corrosion.
pushed-out pins. No
Connect all wiper motor connectors and make sure The system is operating correctly at this
they seat correctly. time. Concern may have been caused by a
loose or corroded connector. TEST the
PINPOINT TEST B: THE WIPERS ARE INOPERATIVE - REAR WINDOW 824

Operate the system and verify the concern is still system for normal operation.
present.
Pinpoint Test C: ThWipers Stay on Continuously - Windshield
Normal Operation
Under normal operation, the wiper motor receives open and ground inputs from the multifunction switch
through circuits CRW08 (VT/OG), CRW17 (GN/VT), CRW18 (VT/WH) and CRW19 (BU/OG) to activate
the wipers to the appropriate speeds.

Windshield wiper motor
PINPOINT TEST C: THE WIPERS STAY ON CONTINUOUSLY - WINDSHIELD

C1 CHECK THE MULTIFUNCTION SWITCH
Yes
Carry out the Multifunction Switch component No
test. INSTALL a new multifunction switch.
Refer to Wiring Diagrams Cell 149 for
component testing.
Did the multifunction switch pass the
component test?
C2 CHECK CIRCUITS CRW08 (VT/OG), CRW17
(GN/VT), CRW19 (BU/OG) AND CRW18 (VT/WH)
Yes
Disconnect: Wiper Motor C125. GO to C3 .
Measure the resistance between ground and
wiper motor: No
C125-1, circuit CRW08 (VT/OG), REPAIR the circuit(s) in question. TEST the
C125-9, circuit CRW17 (GN/VT),
harness side.
C125-10, circuit CRW19 (BU/OG),
harness side.

harness side.

C3 CHECK FOR CORRECT WIPER MOTOR
OPERATION
Yes
Disconnect all wiper motor connectors. INSTALL a new wiper motor. REFER to
Check for: Wiper Motor - Windshield in this section.
corrosion.
pushed-out pins. No
Connect all wiper motor connectors and make The system is operating correctly at this time.
sure they seat correctly. Concern may have been caused by a loose or
Operate the system and verify the concern is still corroded connector. TEST the system for
present. normal operation.
Pinpoint Test D: The Wipers Stay on Continuously - Rear Window
Refer to Wiring Diagrams Cell 81 , Wipers and Washer for schematic and connector information.
Normal Operation
Under normal operation, the rear window wiper motor receives open and ground inputs from the
multifunction switch through circuits CRW20 (GY/YE) and CRW21 (YE/VT) to activate the wiper to the
appropriate modes. The multifunction switch supplies a ground input to the rear wiper motor on circuit
CRW21 (YE/VT) when INT 1 is selected. The multifunction switch supplies ground to the rear wiper motor
on circuits CRW21 (YE/VT) and CRW20 (GY/YE) when INT 2 is selected.

PINPOINT TEST D: THE WIPERS STAY ON CONTINUOUSLY - REAR WINDOW

D1 CHECK THE MULTIFUNCTION SWITCH
Yes
PINPOINT TEST C: THE WIPERS STAY ON CONTINUOUSLY - WINDSHIELD 826

Carry out the multifunction switch component test. No

INSTALL a new multifunction
Refer to Wiring Diagrams Cell 149 for component testing. switch. REFER to Section
Did the multifunction switch pass the component test? 211-05 .
D2 CHECK CIRCUITS CRW20 (GY/YE) AND CRW21
(YE/VT) FOR SHORTS
Yes
Disconnect: Rear Window Wiper Motor C476. GO to D3 .
Measure the resistance between rear window wiper motor
C476-5, circuit CRW20 (GY/YE), harness side and ground; No
and between rear wiper motor C476-1, circuit CRW21 REPAIR the circuit(s) in
(YE/VT), harness side and ground. question. TEST the system for
normal operation.

D3 CHECK FOR CORRECT WIPER MOTOR OPERATION
Yes
Disconnect all wiper motor connectors. INSTALL a new rear window
Check for: wiper motor. REFER to Wiper
liftgate glass open. Motor - Rear Window in this
corrosion. section.
pushed-out pins.
Connect all wiper motor connectors and make sure they seat No
correctly. The system is operating correctly
Operate the system and verify the concern is still present. at this time. Concern may have
Is the concern still present? been caused by a loose or
corroded connector. TEST the
Pinpoint Test E: The High/Low Wiper Speeds Do Not Operate Correctly - Windshield
Normal Operation
through circuits CRW08 (VT/OG), CRW17 (GN/VT) and CRW19 (BU/OG) to activate the wipers in the high
and low speeds.

PINPOINT TEST D: THE WIPERS STAY ON CONTINUOUSLY - REAR WINDOW 827

PINPOINT TEST E: THE HIGH/LOW WIPER SPEEDS DO NOT OPERATE CORRECTLY - WINDSHIELD

E1 CHECK THE MULTIFUNCTION SWITCH
Yes
Refer to Wiring Diagrams Cell 149 for component REFER to Section 211-05 . TEST the
testing. system for normal operation.
Did theultifunction switch pass the component test?
E2 CHECK CIRCUITS CRW08 (VT/OG), CRW17
(GN/VT) AND CRW19 (BU/OG) FOR AN OPEN
Yes
Disconnect: Wiper Motor C125. GO to E3 .
Measure the resistance between multifunction switch
C202, harness side and wiper motor C125, harness side No
using the following chart: REPAIR the circuit(s) in question.
Multifunction Wiper
C202-16 CRW19 C125-10
(BU/OG)
C202-9 CRW08 C125-1
(VT/OG)
C202-12 CRW17 C125-9
(GN/VT)

E3 CHECK CIRCUITS CRW08 (VT/OG), CRW17
(GN/VT) AND CRW19 (BU/OG) FOR A SHORT TO
GROUND
828
Measure the resistance between ground and wiper Yes

motor: GO to E4 .
C125-1, circuit CRW08 (VT/OG), harness side.
C125-9, circuit CRW17 (GN/VT), harness side. No
C125-10, circuit CRW19 (BU/OG), harness REPAIR the circuit(s) in question.
side. TEST the system for normal operation.

E4 CHECK FOR SHORTS IN THE WIPER MOTOR
HARNESS
Yes
Measure the resistance between wiper motor C125, GO to E5 .
harness side, using the following chart:
No
REPAIR the circuit. TEST the system
Wiper Motor Circuits Wiper Motor

C125-10 CRW19 (BU/OG)/ C125-11
CRW18 (VT/WH)
C125-10 CRW19 (BU/OG)/ C125-1
CRW08 (VT/OG)
C125-10 CRW19 (BU/OG)/ C125-9
CRW17 (GN/VT)
C125-11 CRW18 (VT/WH)/ C125-1
CRW08 (VT/OG)
C125-11 CRW18 (VT/WH)/ C125-9
CRW17 (GN/VT)
C125-1 CRW08 (VT/OG)/ C125-9
CRW17 (GN/VT)
Is the resistance greater than 10,000 ohms for all

measurements?
E5 CHECK FOR CORRECT WIPER MOTOR
OPERATION
Yes
Disconnect all wiper motor connectors. INSTALL a new wiper motor. REFER
Check for: to Wiper Motor - Windshield in this
829
corrosion. section.
pushed-out pins.
Connect all wiper motor connectors and make sure they No
seat correctly. The system is operating correctly at this
Operate the system and verify the concern is still time. Concern may have been caused
present. by a loose or corroded connector. TEST
Is the concern still present? the system for normal operation.
Pinpoint Test F: The Intermittent Wiper Speed Does Not Operate Correctly - Windshield
Refer to Wiring Diagrams Cell 81 , Wipers Washers for schematic and connector information.
Normal Operation
through circuits CRW17 (GN/VT), CRW18 (VT/WH) and CRW19 (BU/OG) to activate the wipers to the
appropriate intermittent speeds.

PINPOINT TEST F: THE INTERMITTENT WIPER SPEED DOES NOT OPERATE CORRECTLY - WINDSHIELD

F1 VERIFY IF THE VEHICLE IS EQUIPPED WITH
RAIN SENSITIVE WIPERS
Yes
NOTE: If sent here from Pinpoint Test I, GO to F2. GO to Pinpoint Test I .
Inspect the vehicle for rain sensitive wipers. No

Is the vehicle equipped with rain sensitive wipers? GO to F2 .
F2 CHECK THE MULTIFUNCTION SWITCH
Yes
Refer to Wiring Diagrams Cell 149 for component REFER to Section 211-05 . TEST the
testing. system for normal operation.
test?
F3 CHECK CIRCUITS CRW17 (GN/VT), CRW18
(VT/WH) AND CRW19 (BU/OG) FOR AN OPEN

Disconnect: Wiper Motor C125. Yes

Measure the resistance between multifunction switch GO to F4 .
C202, harness side and wiper motor C125, harness side
REPAIR the circuit(s) in question.
Multifunction Wiper
C202-12 CRW17 C125-9
(GN/VT)
C202-11 CRW18 C125-11
(VT/WH)
C202-16 CRW19 C125-10
(BU/OG)

F4 CHECK CIRCUITS CRW17 (GN/VT), CRW18
(VT/WH) AND CRW19 (BU/OG) FOR A SHORT TO
GROUND
Yes
Measure the resistance between ground and wiper GO to F5 .
motor:
C125-9, circuit CRW17 (GN/VT), harness side. No
C125-10, circuit CRW19 (BU/OG), harness REPAIR the circuit(s) in question.
side. TEST the system for normal operation.
C125-11, circuit CRW18 (VT/WH), harness
side.

F5 CHECK FOR SHORTS IN THE WIPER MOTOR
HARNESS
PINPOINT TEST F: THE INTERMITTENT WIPER SPEED DOES NOT OPERATE CORRECTLY831
- WINDSH
Measure the resistance between wiper motor C125, Yes

harness side, using the following chart: GO to F6 .
No
REPAIR the circuit. TEST the system
Wiper Motor Circuits Wiper Motor
C125-10 CRW19 (BU/OG)/ C125-11
CRW18 (VT/WH)
C125-10 CRW19 (BU/OG)/ C125-1
CRW08 (VT/OG)
C125-10 CRW19 (BU/OG)/ C125-9
CRW17 (GN/VT)
C125-11 CRW18 (VT/WH)/ C125-1
CRW08 (VT/OG)
C125-11 CRW18 (VT/WH)/ C125-9
CRW17 (GN/VT)
C125-1 CRW08 (VT/OG)/ C125-9
CRW17 (GN/VT)
Is the resistance greater than 10,000 ohms for all

measurements?
F6 CHECK FOR CORRECT WIPER MOTOR
OPERATION
Yes
Disconnect all wiper motor connectors. INSTALL a new wiper motor. REFER
Check for: to Wiper Motor - Windshield in this
corrosion. section.
pushed-out pins.
Connect all wiper motor connectors and make sure they No
Operate the system and verify the concern is still time. Concern may have been caused
present. by a loose or corroded connector. TEST
Pinpoint Test G: The Intermittent Wiper Speed Does Not Operate Correctly - Rear Window
Normal Operation
Under normal operation, the rear window wiper motor receives open and ground inputs from the
multifunction switch through circuits CRW20 (GY/YE) and CRW21 (YE/VT) to activate the wiper to the
appropriate modes. The multifunction switch supplies a ground input to the rear wiper motor on circuit
CRW21 (YE/VT) when INT 1 is selected. The multifunction switch supplies ground to the rear wiper motor

on circuits CRW21 (YE/VT) and CRW20 (GY/YE) when INT 2 is selected.

PINPOINT TEST G: THE INTERMITTENT WIPER SPEED DOES NOT OPERATE CORRECTLY - REAR WINDOW

G1 VERIFY REAR WASHER PUMP OPERATION
Yes
Activate the rear washer pump.
Does the rear washer pump activate? No
G2 CHECK THE MULTIFUNCTION SWITCH
Yes
testing.
test?
G3 CHECK FOR A SHORT BETWEEN CIRCUITS
CRW20 (GY/YE) AND CRW21 (YE/VT)
Yes
Measure the resistance between rear window wiper GO to G4 .
C476-5, circuit CRW20 (GY/YE), harness side and
rear window wiper C476-1, circuit CRW21 No
(YE/VT), harness side. REPAIR the circuit. TEST the system for
normal operation.

G4 CHECK FOR CORRECT WIPER MOTOR
OPERATION
Yes
Disconnect all wiper motor connectors. INSTALL a new rear window wiper motor.
Check for: REFER to Wiper Motor - Rear Window in
PINPOINT TEST G: THE INTERMITTENT WIPER SPEED DOES NOT OPERATE CORRECTLY833
- REAR W
liftgate glass open. this section.

corrosion.
pushed-out pins. No
Connect all wiper motor connectors and make sure The system is operating correctly at this
they seat correctly. time. Concern may have been caused by a
Operate the system and verify the concern is still loose or corroded connector. TEST the
present. system for normal operation.
Pinpoint Test H: The Washer Pump is Inoperative
Normal Operation
Under normal operation, the windshield washer pump motor is grounded through internal relays in the wiper
motors using circuits CRW14 (BU/WH) and CRW12 (GY/OG). The multifunction switch provides input to
the windshield wiper motor through circuit CRW07 (GY/BN) to activate the windield washer. The windshield
wiper motor activates the internal relay and then provides power through circuit CRW14 (BU/WH). When the
rear window washer is activated, the internal relay in the rear window wiper motor provides power through
circuit CRW12 (GY/OG).

Windshield washer pump motor
PINPOINT TEST H: THE WASHER PUMP IS INOPERATIVE

H1 CHECK CIRCUIT CRW14 (BU/WH) FOR GROUND
Yes
Disconnect: Washer Pump Motor C1357. GO to H3 .
Ignition ON.
Measure the resistance between washer pump C1357-2, circuit No
CRW14 (BU/WH), harness side and ground. GO to H2 .


H2 CHECK CIRCUIT CRW14 (BU/WH) FOR AN OPEN
Yes
Disconnect: Windshield Wiper Motor C125.
Measure the resistance between windshield wiper motor C125-7, No
circuit CRW14 (BU/WH), harness side and washer pump C1357-2, REPAIR the circuit. TEST
circuit CRW14 (BU/WH), harness side. the system for normal
operation.

H3 CHECK CIRCUIT CRW12 (GY/OG) FOR GROUND
Yes
Measure the resistance between washer pump C1357-1, circuit GO to H6 .
CRW12 (GY/OG), harness side and ground.
No
GO to H4 .

H4 CHECK CIRCUIT CRW12 (GY/OG) FOR AN OPEN
Yes
Disconnect: Rear Window Wiper Motor C476.
Measure the resistance between rear window wiper motor C476-4, No
circuit CRW12 (GY/OG), harness side and washer pump C1357-1, REPAIR the circuit. TEST
circuit CRW12 (GY/OG), harness side. the system for normal
operation.

H5 CHECK CIRCUIT GD149 (BK/GY) FOR AN OPEN
PINPOINT TEST H: THE WASHER PUMP IS INOPERATIVE 835

Measure the resistance between rear window wiper motor C476-3, Yes
circuit GD149 (BK/GY), harness side and ground. GO to H15 .
No
REPAIR the circuit. TEST
operation.

H6 CHECK CIRCUIT CRW14 (BU/WH) FOR VOLTAGE
Yes
Measure the voltage between washer pump C1357-2, circuit
CRW14 (BU/WH), harness side and ground while depressing the No
multifunction switch to the WASH position. GO to H7 .

H7 CHECK CIRCUIT CRW14 (BU/WH) FOR A SHORT TO
GROUND
Yes
Disconnect: Windshield Wiper Motor C125.
CRW14 (BU/WH), harness side and ground. REPAIR the circuit. TEST
operation.

H8 CHECK THE MULTIFUNCTION SWITCH
Yes
Disconnect: Multifunction Switch C202. GO to H9 .
Carry out the Multifunction Switch component test.
No
Refer to Wiring Diagrams Cell 149 for component testing. INSTALL a new

Did the multifunction switch pass the component test? multifunction switch.
TEST the system for
normal operation.
H9 CHECK CIRCUIT CRW07 (GY/BN) FOR AN OPEN OR SHORT
TO GROUND
Yes
Measure the resistance between windshield wiper motor C125-12, GO to H14 .
circuit CRW07 (GY/BN), harness side and multifunction switch
C202-10, circuit CRW07 (GY/BN), harness side; and between No
multifunction switch C202-10, circuit CRW07 (GY/BN), harness REPAIR the circuit. TEST
side and ground. the system for normal
operation.
Is the resistance less than 5 ohms between the multifunction

switch and wiper motor; and greater than 10,000 ohms between
the multifunction switch and ground?
H10 CHECK CIRCUIT CRW12 (GY/OG) FOR VOLTAGE
Yes
Measure the voltage between washer pump C1357-1, circuit INSTALL a new washer
CRW12 (GY/OG), harness side and ground while depressing the pump. TEST the system
multifunction switch to the REAR WASH position. for normal operation.
No
GO to H11 .

H11 CHECK CIRCUIT CRW12 (GY/OG) FOR A SHORT TO
GROUND
Yes
Disconnect: Rear Window Wiper Motor C476.
CRW12 (GY/OG), harness side and ground. REPAIR the circuit. TEST
operation.


H12 CHECK THE MULTIFUNCTION SWITCH
Yes
Disconnect: Multifunction Switch C202. GO to H13 .
Carry out the Multifunction Switch component test.
No
Refer to Wiring Diagrams Cell 149 for component testing. INSTALL a new
Did the multifunction switch pass the component test? multifunction switch.
TEST the system for
normal operation.
H13 CHECK CIRCUIT CRW20 (GY/YE) FOR AN OPEN OR
SHORT TO GROUND
Yes
Measure the resistance between rear window wiper motor C476-5, GO to H15 .
circuit CRW20 (GY/YE), harness side and multifunction switch
C202-14, circuit CRW20 (GY/YE), harness side; and between No
multifunction switch C202-14, circuit CRW20 (GY/YE), harness REPAIR the circuit. TEST
side and ground. the system for normal
operation.
Is the resistance less than 5 ohms between the multifunction

switch and wiper motor; and greater than 10,000 ohms between
the multifunction switch and ground?
H14 CHECK THE WINDSHIELD WIPER MOTOR
Yes
Disconnect the wiper motor connectors. INSTALL a new
Check for: windshield wiper motor.
liftgate glass open. REFER to Wiper Motor -
corrosion. Windshield in this section.
pushed-out pins. TEST the system for
Connect all wiper motor connectors and make sure they seat normal operation.
correctly.
Is the concern still present? REPAIR the circuit. TEST
operation.
H15 CHECK THE REAR WINDOW WIPER MOTOR

Disconnect the wiper motor connectors. Yes

Check for: INSTALL a new rear
liftgate glass open. window wiper motor.
corrosion. REFER to Wiper Motor -
Rear Window in this
ul> section. TEST the system
pushed-out pins.
Connect all wiper motor connectors and make sure they seat No
correctly. REPAIR the circuit. TEST
Operate the system and verify the concern is still present. the system for normal
Is the concern still present? operation.
Pinpoint Test I: The Rain Sensitive Wipers Are Inoperative
Normal Operation
Voltage is supplied to the rain sensor when the ignition is ON. The rain sensor sends data to the wiper motor
on a dedicated circuit. When the multifunction switch is in one of the 5 auto/intermittent settings, the rain
sensitive wipers activate.
The rain sensor optically senses water on the windshield. An infrared beam lights a section of the windshield.
The intensity of the reflected beam is measured and compared to the intensity of the transmitted beam. When
there is water on the surfe of the windshield, the beam distorts, reducing the intensity of the beam. When the
beam is not reflected completely, it is interpreted as rain on the windshield and the windshield wipers activate
based on the sensitivity setting.
If a fault is detected with the rain sensor input by the windshield wiper motor, the wiper motor switches to a
default intermittent mode. The timing of the wipers correspond to a standard intermittent setting based on the
selection on the multifunction switch.
A gel-type lens is used as the interface between the rain sensor and the windshield. If the lens is missing or
damaged, the rain sensing wipers may be inoperative. If the rain sensitive wipers are inoperative and do not
default to the intermittent mode, inspect the rain sensor and confirm that the gel-type lens over the rain sensor
is undamaged.

Fuse
Wiper blades
Rain sensor mounting bracket not secured to the windshield
Rain sensor gel-type lens
Rain sensor
Foreign material on windshield, such as dirt, dust or bugs
Damaged windshield
Wiper motor
SJB

PINPOINT TEST I: THE RAIN SENSITIVE WIPERS ARE INOPERATIVE

I1 CHECK THE INPUT FROM THE
MULTIFUNCTION SWITCH
Yes
Ignition ON. GO to I2 .
Cycle the multifunction switch from off through
each of the auto/intermittent settings, waiting 10 No
seconds between cycling the switch to the next GO to Pinpoint Test F .
setting.
Set the multifunction switch to the wipers off
setting.
Do the wipers cycle when the switch is changed
to each setting?
I2 CHECK THE RAIN SENSITIVE WIPERS FOR
DEFAULT INTERMITTENT MODE
Yes
NOTE: Make sure the windshield is dry when GO to I9 .
carrying out this step.
NOTE: The windshield wipers activate when the No
multifunction switch is cycled through the GO to I3 .
auto/intermittent settings. The initial wiper
activation after changing the setting should not be
considered part of an intermittent wiper operation.
Cycle the multifunction switch to auto/intermittent
setting 5, the most sensitive to moisture.
Do the wipers default to a standard intermittent
setting?
I3 CHECK THE WINDSHIELD FOR DAMAGE
Yes
Ignition OFF. INSTALL a new windshield. REFER to
Inspect the windshield glass for any cracks, pits or Section 501-11 . TEST the system for
other visible damage around the area of the rain normal operation.
sensor.
Is any windshield damage present near the area No
of the rain sensor? GO to I4 .
I4 CHECK THE WINDSHIELD GLASS FOR
STREAKING
Yes
Ignition ON. GO to I5 .
Turn the multifunction switch to the low speed
wiper setting and while applying water to the No
windshield surface. Observe the wipe quality, GO to I7 .
especially around the area or the rain sensor.
Is any streaking present on the windshield
around the area of the rain sensor?
I5 CHECK THE WINDSHIELD WIPER BLADES
FOR STREAKING
PINPOINT TEST I: THE RAIN SENSITIVE WIPERS ARE INOPERATIVE 840

Ignition OFF. Yes

Clean the windshield glass with glass cleaner. GO to I6 .
Clean the wiper blades with isopropyl alcohol
swabs. Wipe the entire length of the wiper blades. No
Ignition ON. INSTALL new wiper blades. GO to I6 .
Turn the multifunction switch to the low speed
wiper setting and while applying water to the
windshield surface. Observe the wipe quality,
especially around the area or the rain sensor.
Was there noticeable improvement in the wipe
quality after cleaning the glass and the wiper
blades?
I6 RECHECK THE RAIN SENSITIVE WIPERS
OPERATION
Yes
Turn the multifunction switch to the The system is operating correctly at this
auto/intermittent 5 setting (most sensitive to time. The concern may have been caused by
moisture) while applying water on the windshield poor wipe quality on the windshield around
above the rain sensor. the rain sensor.
Do the wipers operate when water is applied to
the windshield surface? No
GO to I7 .
I7 CHECK FOR THE PRESENCE OF THE LENS
GEL
Yes
Ignition OFF. ATTACH the retaining clips. GO to I8 .
Lightly press the rain sensor against the windshield
and release the rain sensor clips. No
Does the rain sensor remain adhered to the The sensor lens is missing or damaged.
windshield? INSTALL a new gel-type lens using the
rain sensor bracket service kit. TEST the
I8 INSPECT THE RAIN SENSOR MOUNTING
AREA
Yes
NOTE: The rain sensor gel-type lens can be GO to I9 .
damaged or contaminated during rain sensor
removal, rain sensor bracket separation or incorrect No
installation. REMOVE the gel-type lens. INSTALL a
new gel-type lens using the rain sensor
From the outside of the vehicle, inspect the area of bracket service kit. TEST the system for
the windshield glass where the rain sensor is normal operation. If the concern is still
mounted. The rain sensor contact area should present, GO to I9 .
appear black, with no bubbles, air pockets or
contaminants between the windshield glass and the
rain sensor.
Does the rain sensor contact area appear black,
with no bubbles, air pockets or contaminants
between the windshield glass and the rain
sensor?
I9 CHECK FOR VOLTAGE TO THE RAIN SENSOR

Ignition OFF. Yes

Disconnect: Rain Sensor C914. GO to I11 .
Ignition ON.
Measure the voltage between the rain sensor No
C914-4, circuit CBP43 (GY), harness side and VERIFY SJB fuse 43 (10A) is OK. If OK,
ground. GO to I10 . If not OK, REFER to the
Wiring Diagrams manual to identify the

I10 CHECK THE RAIN SENSOR VOLTAGE
SUPPLY CIRCUIT FOR AN OPEN
Yes
Disconnect: SJB C2280B.
Measure the resistance between the rain sensor No
C914-4, circuit CBP43 (GY), harness side and the REPAIR the circuit. TEST the system for
SJB C2280B-3, circuit CBP43 (GY), harness side. normal operation.

I11 CHECK THE RAIN SENSOR GROUND
CIRCUIT FOR AN OPEN
Yes
Measure the resistance between the rain sensor
C914-1, circuit GD133 (BK), harness side and No
ground. REPAIR the circuit. TEST the system for
normal operation.

I12 CHECK THE RAIN SENSOR SIGNAL CIRCUIT

Yes
Disconnect: Wiper Motor C125. REPAIR the circuit. TEST the system for
Measure the voltage between the rain sensor
C914-2, circuit VRW06 (GN/WH), harness side No
and ground. GO to I13 .

Yes
Measure the resistance between the rain sensor
C914-2, circuit VRW06 (GN/WH), harness side No
and ground. REPAIR the circuit. TEST the system for
normal operation.

FOR AN OPEN
Yes
Measure the resistance between the rain sensor GO to I15 .
C914-2, circuit VRW06 (GN/WH), harness side
and the wiper motor C125-4, circuit VRW06 No
(GN/WH), harness side. REPAIR the circuit. TEST the system for
normal operation.

I15 CHECK FOR CORRECT RAIN SENSOR

OPERATION
Yes
Check for: INSTALL a new rain sensor. REFER to
corrosion. Rain Sensor . TEST the system for normal
pushed-out pins. operation. If the concern is still present,
Connect the rain sensor connector and make it seats INSTALL a new wiper motor. REFER to
correctly. Wiper Motor - Windshield in this section.
Operate the system and determine if the concern is TEST the system for normal operation.
still present.
Is the concern still present? No
The system is operating correctly at this
time. The concern may have been caused by
a loose or corroded connector.
I16 CHECK FOR CORRECT SJB OPERATION
Yes
Check for: 419-10 . TEST the system for normal
pushed-out pins.
Connect all the SJB connectors and make sure they No
Operate the system and determe if the concern is time. The concern may have been caused by
still present. a loose or corroded connector.
Pinpoint Test J: The Headlamps Do Not Illuminate When the Wipers are On
Refer to Wiring Diagrams Cell 81 , Front Wipers and Washers for schematic and connector information.
Normal Operation
The Smart Junction Box (SJB) sends a 12-voltage reference signal on circuit CRW01 (WH) to the wiper
motor module in order to monitor the status of the wipers. When the headlamp control switch is in the
AUTOLAMP position and the wipers are on, the wiper motor module will pull the voltage reference signal
low. Within 10 seconds, the SJB will activate the headlamps.
DTC B2008 (Wipers On Signal Circuit Short to Ground) - Sets when a short to ground is detected on
the wiper motor status input circuit.

SJB
PINPOINT TEST J: THE HEADLAMPS DO NOT ILLUMINATE WHEN THE WIPERS ARE ON

J1 CHECK CIRCUIT CRW01 (WH) FOR VOLTAGE

Yes
Disconnect: Windshield Wiper Motor C125. INSTALL a new windshield
Ignition ON. wiper motor. REFER to Wiper
Measure the voltage between windshield wiper motor C125-2, Motor - Windshield in this
circuit CRW01 (WH), harness side and ground. section. TEST the system for
normal operation.
No
GO to J2 .

J2 CHECK CIRCUIT CRW01 (WH) FOR AN OPEN OR
SHORT TO GROUND
Yes
Disconnect: SJB C2280F.
Measure the resistance between SJB C2280F-8, circuit CRW01 No
(WH), harness side and windshield wiper motor C125-2, REPAIR the circuit. TEST the
circuit CRW01 (WH); then between SJB C2280F-8, circuit system for normal operation.
CRW01 (WH), harness side and ground.
Is the resistance less than 5 ohms between the SJB and

windshield wiper motor; and greater than 10,000 ohms
between the SJB and ground?
J3 CHECK FOR CORRECT MODULE OPERATION
Yes
Disconnect all the SJB connectors. INSTALL a new SJB . REFER
Check for: to Section 419-10 . CLEAR the
corrosion. DTCs. REPEAT the SJB
pushed-out pins. self-test.
Connect all the SJB connectors and make sure they are seated
correctly. No
Is the concern still present? correctly at this time. Concern
may have been caused by a
self-test.
PINPOINT TEST J: THE HEADLAMPS DO NOT ILLUMINATE WHEN THE WIPERS ARE ON 845
PINPOINT TEST J: THE HEADLAMPS DO NOT ILLUMINATE WHEN THE WIPERS ARE ON 846
Wiper Blade and Pivot Arm Adjustment - Windshield
1. Cycle and park the windshield wipers.
2. Verify the distance between the outer tip of the (1) RH windshield wiper blade and the (3) edge of the
cowl panel grille and between the outer tip of the (2) LH windshield wiper blade and the (3) edge of
the cowl panel grille are within specifications.
3. If the distance is not within specification, remove the windshield wiper pivot arm and reposition to
specification. For additional information, refer to Wiper Pivot Arm - Front in this section.
Wiper Blade and Pivot Arm Adjustment - Windshield 847

Wiper Blade and Pivot Arm Adjustment - Rear
1. Cycle and park the rear window wiper pivot arm and blade.
2. Check the rear window wiper park measurement. If not within specification, remove the rear window
wiper pivot arm and reposition to the correct location. For additional information, refer to Wiper Pivot
Arm - Rear in this section.
Wiper Blade and Pivot Arm Adjustment - Rear 848

Wiper and Washer System - Exploded View
Front Wiper System

1 - Wiper pivot arm nut covers (2 required)
2 W707014 Wiper pivot arm nuts
3 17526 Wiper pivot arms (LH and RH)
4 N808988 Wiper pivot arm linkage bolts (3 required)
5 17508A Wiper pivot arm linkage assembly (includes wiper
motor)
6 - Wiper motor crank nut
7 - Wiper motor attachment bolt (3 required)
8 17504 Wiper motor
Rear Wiper System
Wiper and Washer System - Exploded View 849


W708312 Wiper pivot arm nut
2 17526 Wiper pivot arm assembly
3 17C526A Dust boot cover
4 W710357 Handle retaining nut
5 44009 Rear window glass handle
6 - Striker latch nut (2 required)
7 17C426 Striker latch assembly
8 - Wiper motor bracket bolt (4 required)
9 421A00 Latch assembly bolts (2 required)
10 40860 Latch assembly
11 17508 Wiper motor assembly
Washer System
Rear Wiper System 850

Part
1 - Windshield washer pump hoses
2 - Windshield washer pump
3 - Windshield washer reservoir (part of battery tray
assembly)
Washer System 851

Wiper Pivot Arm - Front
NOTICE: To prevent damage to the wiper pivot arm shaft splines, do not rotate the pivot arms into
position manually.
NOTE: The windshield wiper pivot arms must be in the highest position to remove them.
1. Turn the ignition switch to the ON position.
2. Turn the windshield wiper on.
3. Stop the windshield wiper pivot arms at the highest position by turning the ignition switch OFF.
4. Remove the windshield wiper pivot arm.

Remove the pivot arm nut cover.
Remove the nut.
Using a suitable 2-leg puller, remove the windshield wiper pivot arm.
5. NOTE: Make sure the wiper motor is in the PARK position before installation of the wiper pivot
arms.
Adjust the windshield wiper pivot arms. For additional information, refer to Wiper Blade and
Pivot Arm Adjustment - Windshield in this section.
bsp;
Wiper Pivot Arm - Front 852

Wiper Pivot Arm - Front 853

Wiper Pivot Arm - Rear
1. NOTICE: Use a shop towel or similar device to protect the vehicle finish when carrying out the
procedure.
Remove the rear window wiper pivot arm.
Lift the pivot arm nut cover.

Remove the nut.
Using a suitable 2-leg gear puller, remove the rear window wiper pivot arm.
To install, tighten the nut to 12 Nm (106 lb-in).
2. NOTE: This step makes sure that the wiper motor is in the PARK position.
Turn the rear window wiper switch ON and allow the motor to operate for at least one cycle. Turn the
rear window wiper switch to OFF.

Adjust the rear wiper pivot arm. For additional information, refer to Wiper Blade and Pivot
Arm Adjustment - Rear in this section.
Wiper Pivot Arm - Rear 854

Wiper Mounting Arm and Pivot Shaft - Windshield
NOTICE: To prevent damage to the wiper pivot arm shaft splines, do not rotate the pivot arms into
position manually.
NOTE: The windshield wiper pivot arms must be in the highest position on the windshield before they are
removed in order for the wiper mounting arm and pivot shaft assembly to be removed from the vehicle.
1. Remove the cowl grille panel. For additional information, refer to Section 501-02 .
2. Disconnect and position the hood light harness aside.
3. NOTICE: To prevent damage to the windshield glass and hood painted surfaces, make sure to
protect the vehicle components using a shop towel or similar device when carrying out this step.
With the aid of an assistant, remove the hood struts.
Using a suitable method, carefully support the hood in close proximity to the windshield
glass.
4. Remove the mounting arm and pivot shaft assembly.

1. Disconnect the electrical connector and position the wiring harness aside.
5. NOTE: If installing a new wiper mounting arm and pivot shaft assembly or windshield wiper motor,
it will be necessary to temporarily connect the wiper motor electrical connector to operate the motor
until the wiper motor crank has rotated approximately 180 degrees from the PARK position (as
shipped).
Wiper Mounting Arm and Pivot Shaft - Windshield 855

Wiper Mounting Arm and Pivot Shaft - Windshield 856

Striker and Wiper Pivot Shaft Assembly - Rear
Removal
1. Remove the rear wiper pivot arm. For additional information, refer to Wiper Pivot Arm - Rear in this
section.
2. Remove the dust boot cover.
3. Remove the nut and the rear window glass handle.
4. Remove the nuts and the rear window striker and wiper pivot shaft assembly.
Installation
2. NOTE: An audible click should be heard as the striker engages the latch.
Push the rear window wiper striker and pivot shaft assembly into the wiper motor. The pivot shaft pin
should be aligned with the hole in the motor disc.
Striker and Wiper Pivot Shaft Assembly - Rear 857

3. Install the rear window wiper motor alignment tool (2L1Z-14A163-AB). If installing a new rear wiper
motor, one is provided with the motor assembly.
1. Make sure the alignment tool fits over the motor disc and striker assembly.
2. Make sure the alignment tool clips are securely engaged.
4. Carefully close the liftgate glass.
5. Open the liftgate. Install the rear window wiper striker and wiper pivot arm mounting assembly nuts.
6. Remove the rear window wiper motor alignment tool.
7. Close the liftgate.
8. Install the rear window wiper pivot shaft nut and handle. Tighten to 18 Nm (159 lb-in).
9. Install the dust boot cover.

10. NOTE: This step makes sure that the wiper motor is in the PARK position.
Turn the rear window wiper switch ON and allow the motor to operate for at least one cycle. Turn the
rear window wiper switch to OFF.
11. Install the rear wiper pivot arm. For additional information, refer to Wiper Pivot Arm - Rear in this
section.
13. Install the liftgate trim panel. For additional information, refer to Section 501-05 .
14. Test the liftgate and liftgate glass for normal operation.

Wiper Mounting Arm and Pivot Shaft Rear
1. Remove the rear wiper pivot arm. For additional information, refer to Wiper Pivot Arm Rear in
this section.

4. Open the liftgate glass.
5. Remove the nuts and the rear window wiper striker and wiper pivot shaft assembly.
6. To install reverse the removal procedure.
Wiper Mounting Arm and Pivot Shaft Rear 860

Wiper Mounting Arm and Pivot Shaft Rear 861

Wiper Motor - Windshield
Removal
1. Remove the mounting arm and pivot shaft. For additional information, refer to Wiper Mounting Arm
and Pivot Shaft - Windshield in this section.
2. Remove the windshield wiper motor crank from the motor assembly.
Remove the windshield wiper motor crank nut.
Using a suitable 2-leg puller, remove the wiper motor crank from the wiper motor shaft.
3. Remove the 3 windshield wiper motor bolts and the wiper motor.
Installation
1. Install the windshield wiper motor to the wiper mounting arm and pivot shaft assembly.
Install the 3 windshield wiper motor bolts and tighten to 15 Nm (133 lb-in).
2. NOTICE: A new wiper motor is shipped in the PARK position. It is important the new wiper
motor shaft position is not disturbed until the wiper motor crank arm is installed in the
following steps. Failure to follow these instructions may result in the wiper arms not parking
correctly when installed into the vehicle.
Install the supplied template (part of 17504) to the wiper mounting arm bracket as shown.
Wiper Motor - Windshield 862

3. NOTE: The alignment marks will allow the crank to be installed correctly in the PARK position.
Using the alignment marks on the template, install the wiper motor crank arm to the wiper motor
shaft.
4. NOTE: Make sure the wiper motor crank-to-wiper motor shaft alignment is not lost while tightening
the wiper motor crank nut.
Using an adjustable wrench as shown to prevent movement of the wiper motor crank, install the
windshield wiper motor crank nut and tighten to 29 Nm (21 lb-ft).
Remove the template and discard.
5. Install the mounting arm and pivot shaft. For additional information, refer to Wiper Mounting Arm
and Pivot Shaft - Windshield in this section.


Wiper Motor - Rear Window
Material
Item Specification
Rear Window Wiper Motor 2L1Z-14A163-AB
Alignment Tool
Removal
1. Remove the rear wiper pivot arm. For additional information, refer to Wiper Pivot Arm - Rear in this
section.
5. Remove the nuts and the rear window striker and wiper pivot shaft assembly.
8. If installing a new rear wiper motor, remove the liftgate window glass latch.
Wiper Motor - Rear Window 865

9. Remove the rear window wiper motor.

Installation
1. If installing a new rear wiper motor, install the liftgate window glass latch.
1. Tighten bolts to 8 Nm (71 lb-in).
2. NOTE: An audible click should be heard as the striker engages the latch.
Push the rear window wiper striker and pivot shaft assembly into the wiper motor. The pivot shaft pin
should be aligned with the hole in the motor disc.
3. Install the rear window wiper motor alignment tool. If installing a new rear wiper motor, one is
provided with the motor assembly.
1. Make sure the alignment tool fits over the motor disc and striker assembly.
2. Make sure the alignment tool clips are securely engaged.

4. Install the rear wiper motor.

1. Tighten the bolts to 11 Nm (97 lb-in).
2. Connect the electrical connectors.
5. Carefully close the liftgate glass.
6. Open the liftgate. Install the rear window wiper striker and wiper pivot arm mounting assembly nuts.
8. Install the rear window glass handle and nut.

9. Install the dust boot cover.

10. Install the rear wiper pivot arm. For additional information, refer to Wiper Pivot Arm - Rear in this
section.
12. Remove the rear window wiper motor aligning tool.
14. Install the liftgate trim panel. Refer to Section 501-05 .
15. Test the liftgate and liftgate glass for normal operation.

Rain Sensor
NOTE: Vehicle without Headlamp Control Module 2 (HCM-2) shown, vehicle with HCM-2 similar.

1 - Electrical connector (part of 17C712)
2 17D547 Rain sensor
3 17D550 Rain sensor cover
Removal
NOTE: If reinstalling the original rain sensor, a new lens/bracket service kit (19G382) must be acquired prior
to performing this procedure.
1. On vehicles equipped with a Headlamp Control Module 2 (HCM-2), remove the HCM-2 . For
additional information, refer to Section 417-01 .
2. On vehicles equipped with only a rain sensor, remove the rain sensor cover.
3. Disconnect the rain sensor electrical connector.
4. NOTE: Lightly press the rain sensor against the windshield to relieve the clip tension.
Release the 2 rain sensor retaining clips and remove the rain sensor.
Rain Sensor 869

Installation
Reinstalling the original rain sensor
NOTICE: Do not touch the rain sensor lens-to-windshield contact area or allow it to become
contaminated with dust or debris. Touching or contaminating the rain sensor lens will result in the rain
sensitive wiper feature being inoperative or working incorrectly.
1. Disengage the 3 rain sensor plastic clips and separate the electronics backing plate from the rain
sensor lens.
Discard the rain sensor lens.
2. Disengage the 3 rain sensor plastic clips on the rain sensor lens protective backing and separate the
rain sensor protective backing from the new rain sensor lens.
3. NOTE: Do not remove the white rain sensor lens protective cover at this time.
Install the rain sensor lens onto the electronics backing plate.
Rain Sensor 870

All rain sensors
4. Remove the white rain sensor lens protective cover from the rain sensor lens.
5. Clean any residual rain sensor lens material from the rain sensor viewing window.
6. Install the rain sensor onto the rain sensor mounting bracket, making sure that the alignment tab on
the rain sensor is aligned with the notch on the mounting bracket.
Press the metal rain sensor mounting bracket clips to engage the clips onto the mounting
bracket.
7. Connect the rain sensor electrical connector.
8. On vehicles equipped with only a rain sensor, install the rain sensor cover.
Rain Sensor 871

9. On vehicles equipped with a Headlamp Control Module 2 (HCM-2), install the HCM-2 . For
Rain Sensor 872

Rain Sensor Bracket
NOTE: The rain sensor bracket primer and adhesive are not included in service kit (part number 19G382) and
will have to be ordered separately. The rain sensor bracket primer and adhesive part numbers and ordering
instructions are available in the parts ordering system.
NOTE: The rain sensor bracket adhesive will take at least 6 hours to dry.
1. Disconnect the rain sensor electrical connector.
2. NOTICE: Make sure not to scratch the windshield glass.
Using a razor blade, carefully remove any residual glue from the windshield glass.
3. Using a clean cloth, wipe the windshield glass to remove any loose glue particles and any residual
rain sensor lens material.
4. Apply specified primer onto a clean cloth.
5. Insert a cotton swab, or equivalent, onto the wet area of the cloth.
6. NOTICE: Do not apply primer to the rain sensor view window area.
Using the cotton swab, or equivalent, apply the primer onto the contact area of the rain sensor
mounting bracket area of the windshield glass.
7. NOTE: Apply the adhesive to the side of the rain sensor bracket that is opposite of the notch and that
does not contain numbers and letters.
Using a 3M EPX Plus II applicator or equivalent, apply a 2 to 3 mm (0.078 in to 0.118 in) bead of
specified adhesive to the rain sensor mounting bracket.
Rain Sensor Bracket 873

8. NOTE: If the rain sensor mounting bracket is not mounted in the correct location on the windshield
glass, the rain sensor trim cover will not install correctly.
Apply the rain sensor mounting bracket onto the windshield making sure that the notch on the bracket
is in the 1 o'clock position and that the bracket is centered around the rain sensor view window area.
9. NOTE: Do not apply masking tape onto the rain sensor view window area.
Apply masking tape onto the rain sensor mounting bracket and the windshield glass in order to hold
the bracket onto the windshield.
10. Allow the adhesive to dry for at least 6 hours.
11. Disengage the metal rain sensor mounting clips from the old rain sensor bracket and separate the old
rain sensor bracket from the rain sensor.
Discard the old rain sensor bracket, it is not to be reused.
12. Install the rain sensor. For additional information, refer to Rain Sensor in this section.


Washer Pump
WARNING: Carefully read cautionary information on product label. For emergency medical
information seek medical advice. In the USA or Canada on Ford/Motorcraft products call:
1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if
available. Failure to follow these instructions may result in serious personal injury.
NOTICE: When servicing the windshield washer pump, be careful not to damage the windshield
washer pump seal.
NOTICE: Do not operate the windshield washer pump before filling the windshield washer reservoir.
Failure to do so may result in premature pump failure.
1. Remove the RH headlamp assembly. For additional information, refer to Section 417-01 .
2. Position aside the shield as necessary to gain access to the washer pump.
3. Disconnect the windshield washer reservoir hoses.
4. Disconnect the windshield washer pump electrical connector.
5. Remove the windshield washer pump.
Washer Pump 876

Washer Reservoir
NOTE: The washer reservoir is integrated with the battery tray and cannot be serviced separately.
1. Remove the vehicle battery tray. For additional information, refer to Section 414-01 .
Washer Reservoir 877

SECTION 501-17: Roof Opening Panel 2011 Expedition, Navigator Workshop Manual
Item Specification
Roof Opening Panel Alignment
Roof opening panel alignment, glass front edge to roof opening panel -1.5-0 mm
(-0.059-0 in)
Roof opening panel alignment, glass rear edge to roof opening panel 0-1.5 mm
(0-0.059 in)
Roof opening panel air deflector screws 1 9
Roof opening panel frame bolts 10 89
Roof opening panel glass screws 4 35
Roof opening panel motor screws 4 35
Roof opening panel trough guide retaining screws 1 9
Washer Reservoir 878

Roof Opening Panel
The roof opening panel system consists of the following components:
Glass seal
Roof opening panel air deflector
Roof opening panel control switch (part of overhead console)
Roof opening panel frame
Roof opening panel frame drain hose
Roof opening panel lifter assembly
Roof opening panel motor/module
Roof opening panel rear trough guides
Roof opening panel shield
Roof opening panel water trough
Wiring harness
Roof Opening Panel Operation
The roof opening panel assembly uses an integrated motor and module to operate the roof opening panel. The
roof opening panel is an electronically operated glass panel that has one-touch open, one-touch close and
one-touch vent features.
To open the roof opening panel, press and release the slide control switch. The roof opening panel will open
automatically. The roof opening panel movement can be stopped at any time by pressing the switch again.
To vent the roof opening panel, the roof opening panel must first be in the CLOSED position. When the roof
opening panel is in the CLOSED position, press and release the tilt control switch. The roof opening panel
will move to the VENT position automatically. To close the roof opening panel from the VENT position, pull
and hold the tilt control switch until the glass stops moving.
To close the roof opening panel, pull and release the slide or tilt control switch. The roof opening panel will
close automatically. The roof opening panel movement can be stopped at any time by activating the slide or
tilt control switch in either direction.
Bounce-Back
The roof opening panel has a bounce-back feature. If an obstacle has been detected in the roof opening panel
as the sliding glass is closing, the roof opening panel will automatically open and stop at a predetermined
position.
Security Override
To override a bounce-back condition (to overcome the resistance of ice on the roof opening panel seal for
example), within 2 seconds of a bounce-back event, pull and hold the slide or tilt control switch. The closing
force will begin to increase each time the roof opening panel is closed for the first 3 closing cycles
(bounce-back will still be enabled).
Roof Opening Panel Drain Hose Routing
NOTE: Passenger side shown, driver side similar.
Roof Opening Panel 879

Roof Opening Panel Drain Hose Routing 880

Roof Opening Panel
Special Tool(s)
Flex Probe Kit


The roof opening panel assembly uses an integrated motor and module to operate the roof opening panel. The
roof opening panel motor and module are installed new as an assembly. The roof opening panel is an
electronically operated glass panel that can be opened, closed or vented by the roof opening panel switch.
The roof opening panel has a comfort stop position, which is 70 mm (2.75 in) from the full OPEN position,
and is controlled by the roof opening panel motor/module. The comfort stop position reduces wind rumbling
noise that may occur when the vehicle is operated with the roof opening panel in the full OPEN position.
When the roof opening panel is opened in either one-touch open or manual mode, it will stop at the comfort
stop position first. In manual mode, the roof opening panel can be opened to full open from comfort stop by
releasing the switch, then pressing and holding it until the roof opening panel is in the full OPEN position. In
one-touch open mode, the roof opening panel can be opened to full open from comfort stop by momentarily
pressing the slide switch.
The roof opening panel motor must be initialized when repairs are carried out on any part of the roof opening
panel system, including: whenever the roof opening panel motor has been removed from the roof opening
panel system, the roof opening panel glass has been removed from the roof opening panel system, the roof
opening panel assembly has been remofrom the vehicle, a new roof opening panel motor has been installed, a
new roof opening panel glass has been installed or a new roof opening panel assembly has been installed.
Roof opening panel

Roof opening panel frame Battery Junction Box (BJB) fuse 64

Roof opening panel drain hoses (30A)
Roof opening panel lifter Smart Junction Box (SJB) fuse 41 (15A)
assemblies Circuitry
Roof opening panel water trough Accessory delay relay
Roof opening panel rear trough Roof opening panel motor and module
guides assembly
Roof opening panel air deflector Roof opening panel control switch
assembly
Roof opening panel seal
Roof opening panel shield
4. If the concern is not visually evident, verify the symptom and GO to Symptom Chart - Roof Opening
Panel or GO to Symptom Chart - NVH .
Symptom Chart - Roof Opening Panel
Symptom Chart - Roof Opening Panel
Symptom Chart - NVH
Symptom Chart - NVH

the symptom, refer back to Section 100-04 for the next likely system and continue diagnosis.
The roof opening panel has excessive wind noise
Roof opening panel alignment

Roof opening panel seal
The roof opening panel rattles
Roof opening panel glass

Roof opening panel tracks
Roof opening panel air deflector assembly
Roof opening panel rear trough guides
Roof opening panel lifter assemblies

Headliner
Motor pad
Rear side brackets
The roof opening panel is noisy during operation
Roof opening panel

Roof opening panel alignment
Roof opening panel motor/module assembly
Pinpoint Tests
Pinpoint Test A: The Roof Opening Panel Has Excessive Wind Noise
Normal Operation
During normal operation, when the roof opening panel glass is completely closed, it is flush with the roof
panel and correctly sealed.

Roof opening panel glass alignment
Roof opening panel glass seal(s)
PINPOINT TEST A: THE ROOF OPENING PANEL HAS EXCESSIVE WIND NOISE

A1 VERIFY ROOF OPENING PANEL
NOISE
Yes
Road test the vehicle with the roof GO to A4 .
opening panel in the CLOSED and
OPEN positions. No
Is the wind noise present only in the GO to A2 .
OPEN position?
A2 CHECK THE ROOF OPENING
PANEL ALIGNMENT
Yes
Make sure the roof opening panel glass GO to A3 .
is centered and flush with the roof line.
Is the roof opening panel aligned No
correctly? ALIGN the roof opening panel. REFER to Roof
Opening Panel Alignment in this section.

A3 CHECK THE ROOF OPENING

PANEL WEATHERSTRIP
Yes
NOTE: Make sure the weatherstrip is REFER to Section 501-00 to diagnose other possible
secured to the glass, not cut, cracked, sources of the excessive wind noise.
pinched, loose or obstructed in
CLOSED, VENT and OPEN position. No
INSTALL a new roof opening panel weatherstrip.
Check the roof opening panel REFER to Roof Opening Panel Weatherstrip in this
weatherstrip. section.
Is the roof opening panel
weatherstrip OK?
A4 CHECK THE AIR DEFLECTOR
Yes
Make sure the air deflector is securely GO to A5 .
attached and check for torn and
unsecured tethers. No
Is the air deflector OK? REPAIR or INSTALL new air deflector assembly.
REFER to Air Deflector in this section.
A5 CHECK THE AIR DEFLECTOR FOR
VIBRATION
Yes
Road test the vehicle and check for air CHECK the curvature of the air deflector. The top
deflector vibration. center edge of the air deflector should be approximately
Did the air deflector vibrate? 6-8 mm (0.23-0.31 in) above the roof line at the center
of the vehicle. The curvature of the air deflector may be
modified if necessary by slightly bending it upward or
downward at its center. TEST the system for normal
operation.
No
PARTIALLY close the roof opening panel until the
noise is eliminated. If the noise is eliminated, inform the
customer that changing glass location will eliminate the
wind noise. If the wind noise is not eliminated,
INSTALL a new air deflector. REFER to Air Deflector
in this section.
Pinpoint Test B: The Roof Opening Panel Leaks
Normal Operation
During normal operation, when the roof opening panel glass is completely closed, it is flush with the roof
panel and correctly sealed. The drain channel collects water and drains it through the front drain hose(s)
located in the A-pillar and the rear drain hose(s) located in the C-pillar.
This pinpoint test is intended to diagnosis the following:

Roof opening panel drain hoses
Roof opening panel glass seal(s)
Sealant joints at frame (rail and track assembly) joints
PINPOINT TEST A: THE ROOF OPENING PANEL HAS EXCESSIVE WIND NOISE 884
PINPOINT TEST B: THE ROOF OPENING PANEL LEAKS

B1 VERIFY CUSTOMER OPERATION OF THE ROOF
OPENING PANEL WHEN PARKED
Yes
Make sure the customer is parking with the roof GO to B2 .
opening panel in the CLOSED position.
Is the customer parking with the roof opening panel No
in the CLOSED position? INSTRUCT the customer to refer to the
Owner's Literature for correct operation
of the roof opening panel.
B2 CHECK THE ALIGNMENT OF THE ROOF
OPENING PANEL
Yes
Make sure the roof opening panel glass is centered and GO to B3 .
flush with the roof line.
Is the roof opening panel aligned correctly? No
ALIGN the roof opening panel. REFER
to Roof Opening Panel Alignment in
normal operation.
B3 CHECK THE WEATHERSTRIP CONDITION
Yes
NOTE: The seal has a bonded joint located on the GO to B4 .
passenger side or rear edge. This is not a defect.
No
Make sure the roof opening panel seal is not cracked, INSTALL a new roof opening panel
torn or loose. seal. TEST the system for normal
Check the roof opening panel seal. operation.
Is the roof opening panel seal in good condition and
free from damage?
B4 CHECK THE WATER TROUGH CONDITION
Yes
Check the water trough and guides for damage and/or GO to B5 .
incorrect attachment and function.
Is the water trough OK? No
REPAIR the water trough or INSTALL
a new component as necessary. TEST
B5 CHECK THE DRAIN HOSES
Yes
NOTE: Drain hoses can be viewed with a flashlight by GO to B6 .
removing the headliner lace around the inside opening
and gently pulling down on the headliner. (On some No
vehicles, Velcro-style attachments have been installed REPAIR or INSTALL a new drain
in place of the trim lace.) hose(s). TEST the system for normal
operation.
Make sure the drain hoses are all connected and not
cracked, slit, pinched or obstructed.

Are all the drain hoses present and attached

correctly?
B6 CHECK THE DRAIN HOSES FOR CORRECT
FLOW
Yes
NOTE: Drain hoses must flow downhill and cannot be GO to B7 .
pinched or restricted by headliner or any other trim
components. No
If compressed air was unable to clear
With the panel in the OPEN position, slowly pour the obstruction, LOWER the headliner
water into the water trough area and make sure that the and INSPECT the drain hoses for
same amount of water exits the vehicle at the bottom of correct routing and/or leaks. REPAIR or
the A- and C-pillars. INSTALL a new drain hose(s). TEST
Check the drain hoses for obstructions by blowing the system for normal operation.
compressed air through the drain spouts in the water
trough area, then retest the water.
Are the drain hoses operating correctly?
B7 CHECK THE CONDITION OF THE ROOF
OPENING PANEL FRAME
Yes
Check the roof opening panel frame for damage that INSPECT other areas of the vehicle that
may cause the roof opening panel seal to seat may cause water to enter the roof area,
incorrectly. such as, the windshield or luggage rack
Is the roof opening panel frame OK? if equipped.
No
REPAIR the roof opening panel frame
as necessary. TEST the system for
normal operation.
Pinpoint Test C: The Roof Opening Panel Rattles
Normal Operation
During normal operation, when the roof opening panel is completely closed, it is flush with the roof panel. All
components should be secured correctly.

Roof opening drain channels (water trough) and guides
Roof opening panel shield (sunshade)
Roof opening panel air deflector
Roof opening panel assembly
PINPOINT TEST C: THE ROOF OPENING PANEL RATTLES
PINPOINT TEST B: THE ROOF OPENING PANEL LEAKS 886

C1 CHECK THE ROOF OPENING

PANEL GLASS TIGHTNESS
Yes
With the roof opening panel in the ALIGN the roof opening panel. REFER to Roof Opening
CLOSED position, manually push Panel Alignment in this section. TEST the system for
up and fore/aft on the glass panel. normal operation.
Is the roof opening panel glass
loose? No
GO to C2 .
PANEL TRACKS
Yes
Open the roof opening panel. GO to C3 .
Check the roof opening panel tracks
for obstructions and damage. No
Are the roof opening panel tracks REMOVE all the roof opening panel track obstructions
OK? and REPAIR the roof opening panel tracks. TEST the
PANEL WATER TROUGH AND REAR
TROUGH GUIDES
Yes
Check the roof opening panel water GO to C4 .
trough and rear trough guides for
any loose obstructions. No
Are the roof opening panel water REMOVE all obstructions from the roof opening panel
trough and rear trough guides water trough and INSTALL securely. SECURE the rear
installed securely and free from trough guides or INSTALL new roof opening panel rear
obstructions? trough guides if damaged. REFER to Roof Opening Panel
Rear Trough Guide in this section. TEST the system for
normal operation.
PANEL SHIELD (SUNSHADE)
Yes
Check the roof opening panel shield GO to C5 .
(sunshade) for correct installation
with all 4 tabs in the track channels. No
Is the roof opening panel shield INSTALL the roof opening panel shield correctly. TEST
installed correctly? the system for normal operation.
PANEL AIR DEFLECTOR ASSEMBLY
Yes
Check the roof opening panel air GO to C6 .
deflector assembly for obstructions,
damage and incorrect attachments. No
Is the roof opening panel air REMOVE all obstructions and REPAIR or INSTALL a
deflector assembly OK? new roof opening panel air deflector assembly. REFER to
Air Deflector in this section. TEST the system for normal
operation.
PANEL LIFTER ASSEMBLIES
PINPOINT TEST C: THE ROOF OPENING PANEL RATTLES 887

Verify the roof opening panel lifter Yes

assemblies are free from GO to C7 .
obstructions and damage.
Are the roof opening panel lifter No
assemblies OK? REMOVE all obstructions from the roof opening panel
lifter assemblies and REPAIR any damage. If the lifter
assemblies cannot be repaired, INSTALL a new roof
opening panel frame. REFER to Roof Opening Panel
Frame in this section. TEST the system for normal
operation.
PANEL FRAME ATTACHMENTS
Yes
Check for correct torque and GO to C8 .
installation of the roof opening panel
frame. No
Is the roof opening panel correctly TIGHTEN or REINSTALL the roof opening panel frame.
installed and tightened to REFER to Roof Opening Panel Frame in this section.
specification? TEST the system for normal operation.
PANEL FRAME TO HEADLINER FOR
RATTLES
Yes
Check the roof opening panel frame INSTALL a suitable sound damper material to correct the
to headliner for any interference condition. If the rattle still persists, INSTALL a new roof
condition that would induce a rattle. opening panel frame. REFER to Roof Opening Panel
Is there a condition that will cause Frame in this section. TEST the system for normal
rattles? operation.
No
INSTALL a new roof opening panel frame. REFER to
Roof Opening Panel Frame in this section. TEST the
Pinpoint Test D: The Roof Opening Panel is Noisy During Operation
Normal Operation
During normal operation, the roof opening panel operates smoothly while opening and closing.

Roof opening panel shield (sunshade)
Roof opening panel motor
PINPOINT TEST D: THE ROOF OPENING PANEL IS NOISY DURING OPERATION

D1 CHECK THE ROOF

OPENING PANEL FOR
OBSTRUCTIONS OR DAMAGE
Yes
Check the roof opening panel REMOVE all obstructions. REPAIR any damage or INSTALL a
for any obstructions and new roof opening panel frame. REFER to Roof Opening Panel
damage. Frame in this section. TEST the system for normal operation.
Are there any obstructions
and/or damage? No
GO to D2 .
D2 CHECK THE ROOF
OPENING PANEL OPERATION
Yes
Check the roof opening panel ALIGN the roof opening panel. REFER to Roof Opening Panel
during operation. Alignment in this section. TEST the system for normal
Is the roof opening panel operation.
loose or incorrectly aligned?
No
GO to D3 .
D3 CHECK THE ROOF
OPENING PANEL TRACKS
Yes
Open the roof. GO to D4 .
Check the roof opening panel
tracks for obstructions and No
damage. REMOVE all obstructions and REPAIR any damage. TEST the
Are the roof opening panel system for normal operation.
tracks OK?
D4 CHECK THE ROOF
OPENING PANEL SHIELD
(SUNSHADE)
Yes
Check the roof opening panel GO to D5 .
shield for correct movement.
Is the roof opening panel No
shield moving correctly? REMOVE and REINSTALL the roof opening panel shield.
REFER to Roof Opening Panel Shield in this section. TEST the
D5 CHECK THE ROOF
OPENING PANEL LIFTER
ASSEMBLIES
Yes
Check the roof opening panel GO to D6 .
lifter assemblies for
obstructions and damage. No
Are the roof opening panel REMOVE all obstructions and REPAIR any damage. If lifter
lifter assemblies OK? assemblies cannot be repaired, INSTALL a new roof opening
panel frame. REFER to Roof Opening Panel Frame in this
section. TEST the system for normal operation.
D6 CHECK THE ROOF
OPENING PANEL MOTOR
PINPOINT TEST D: THE ROOF OPENING PANEL IS NOISY DURING OPERATION 889
Remove the roof opening Yes

panel motor/module and leave INSTALL a new roof opening panel motor. REFER to Roof
the electrical connector Opening Panel Motor in this section. TEST the system for
connected. normal operation.
Operate the roof opening
panel to the full OPEN and No
CLOSED position. REINSTALL the roof opening panel motor/module. TEST the
Does the motor make system for normal operation. If the roof opening panel is still
excessive noise? noisy, INSTALL a new roof opening panel frame. REFER to
Roof Opening Panel Frame in this section. If the roof opening
panel is no longer noisy, the system is operating correctly. The
concern may have been caused by an incorrectly installed roof
opening panel motor.
Pinpoint Test E: The Roof Opening Panel Does Not Open or Close
Refer to Wiring Diagrams Cell 101 , Roof Opening Panel for schematic and connector information.
opening panel assembly has been removed from the vehicle, a new roof opening panel motor has been
installed, a new roof opening panel glass has been installed or a new roof opening panel assembly has been
installed. Refer to Roof Opening Panel Motor Initialization in this section.
Normal Operation
The roof opening panel uses an integrated motor and module to operate the roof opening panel. A new roof
opening panel motor/module is installed as an assembly.
The roof opening panel motor/module receives voltage from the accessory delay relay through circuit CBP41
(BU) when the key is in the ACC or RUN position and voltage at all times through circuit SBB64 (VT/RD).
Ground is provided to the roof opening panel motor/module and roof opening panel control switch through
circuit GD138 (BK/WH). When the roof opening panel slide switch is pulled, a ground signal is sent to the
roof opening panel motor/module through circuit CPR40 (YE/OG), which causes the roof opening panel to
close. When the roof opening panel slide switch is pressed, a ground signal is sent to the roof opening panel
motor/module through circuit CPR39 (VT/WH), which causes the roof opening panel to open. When the roof
opening panel tilt switch is pressed, a ground signal is sent to the roof opening panel motor/module through
circuit CPR31 (VT/BN), which causes the roof opening panel to open to the VENT position.
Fuse(s)
Roof opening panel switch

PINPOINT TEST E: THE ROOF OPENING PANEL DOES NOT OPEN OR CLOSE

E1 CHECK THE POWER WINDOW
OPERATION
Yes
Attempt to operate the power windows.
Do the power windows operate? No
REFER to Section 501-11 to diagnose the
inoperative power windows.
E2 CHECK THE MOTOR/MODULE FOR
INITIALIZATION
Yes
Attempt to carry out the roof opening panel GO to E3 .
motor initialization procedure. Refer to Roof
Opening Panel Motor Initialization in this No
section. The system is operating normally at this time.
Is the concern still present and/or does the The roof opening panel motor was not
roof opening panel motor fail to initialize? initialized.
E3 CHECK THE ROOF OPENING PANEL
SWITCH
Yes
Disconnect: Roof Opening Panel Switch
C930. No
Carry out the roof opening panel switch INSTALL a new roof opening panel switch.
component test. TEST the system for normal operation.

component testing.
Is the roof opening panel switch OK?
SWITCH GROUND - CIRCUIT GD138 (BK/WH)
Yes
Measure the resistance between roof opening GO to E5 .
panel switch C930-12, circuit GD138
(BK/WH), harness side and ground. No
operation.
PINPOINT TEST E: THE ROOF OPENING PANEL DOES NOT OPEN OR CLOSE 891
E5 CHECK VOLTAGE TO THE ROOF

OPENING PANEL MOTOR/MODULE -
CIRCUITS CBP41 (BU) AND SBB64 (VT/RD)
Yes
Disconnect: Roof Opening Panel CHECK the roof opening panel motor/module
Motor/Module In-Line C922. jumper harness for loose pins or an open in
Ignition ON. circuits CBP41 (BU) and SBB64 (VT/RD)
Measure the voltage between roof opening between roof opening panel motor/module
panel motor/module in-line C922-2, circuit in-line C922, component side, and roof opening
CBP41 (BU), harness side and ground; and panel motor/module C921, harness side. If the
between roof opening panel motor/module roof opening panel motor/module juer harness is
in-line C922-1, circuit SBB64 (VT/RD), not OK, INSTALL a new roof opening panel
harness side and ground. motor/module jumper harness and TEST the
system for normal operation. If the roof opening
panel motor/module jumper harness is OK, GO
to E6 .
No
VERIFY Battery Junction Box (BJB) fuse 64
(30A) and Smart Junction Box (SJB) fuse (15A)
are OK. If OK, REPAIR the circuit.

measurements?
circuit short. TEST the system for normal
operation.
GROUND - CIRCUIT GD138 (BK/WH)
Yes
Ignition OFF. CHECK the roof opening panel motor/module
Measure the resistance between roof opening jumper harness for loose pins or an open in
panel motor/module in-line C922-4, circuit circuit GD138 (BK/WH) between roof opening
GD138 (BK/WH), harness side and ground. panel motor/module in-line C922, component
side, and roof opening panel motor/module
C921, harness side. If the roof opening panel
motor/module jumper harness is not OK,
INSTALL a new roof opening panel
motor/module jumper harness and TEST the
panel mot/module jumper harness is OK, GO to
E7 .
No
operation.
E7 CHECK CIRCUIT CPR39 (VT/WH) FOR AN
OPEN
Yes
Measure the resistance between roof opening CHECK the roof opening panel motor/module
panel switch C930-6, circuit CPR39 jumper harness for loose pins or an open in
(VT/WH), and roof opening panel circuit CPR39 (VT/WH) between roof opening
motor/module in-line C922-5, circuit CPR39 panel motor/module in-line C922, component
(VT/WH), harness side. side, and roof opening panel motor/module

to E8 .
No
operation.
E8 CHECK CIRCUIT CPR40 (YE/OG) FOR AN
OPEN
Yes
Measure the resistance between roof opening CHECK the roof opening panel motor/module
panel switch C930-8, circuit CPR40 (YE/OG), jumper harness for loose pins or an open in
and roof opening panel motor/module in-line circuit CPR40 (YE/OG) between roof opening
C922-6, circuit CPR40 (YE/OG), harness side. panel motor/module in-line C922, component
to E9 .
No
operation.
E9 CHECK CIRCUIT CPR31 (VT/BN) FOR AN
OPEN
Yes
Measure the resistance between overhead CHECK the roof opening panel motor/module
console C930-3, circuit CPR31 (VT/BN), and jumper harness for loose pins or an open in
roof opening panel motor/module in-line circuit CPR40 (YE/OG) between roof opening
C922-7, circuit CPR31 (VT/BN), harness side. panel motor/module in-line C922, component
to E10 .
No
operation.
MOTOR/MODULE FOR CORRECT
OPERATION
Disconnect all roof opening panel Yes

motor/module connectors. INSTALL a new roof opening panel
Check for: motor/module. REFER to Roof Opening Panel
corrosion. Motor in this section. TEST the system for
bent pins. normal operation.
pushed-out pins.
Connect all roof opening panel motor/module No
connectors and make sure they seat correctly. The system is operating correctly at this time.
Operate the system and verify the concern is Concern may have been caused by a loose or
still present. corroded connector. TEST the system for normal
Is the concern still present? operation.
Pinpoint Test F: The Roof Opening Panel Does Not Open or Close in VENT Position
Refer to Wiring Diagrams Cell 101 , Roof Opening Panel for schematic and connector information.
opening panel assembly has been removed from the vehicle, a new roof opening panel motor has been
installed, a new roof opening panel glass has been installed or a new roof opening panel assembly has been
installed. Refer to Roof Opening Panel Motor Initialization in this section.
Normal Operation
The roof opening panel uses an integrated motor and module to operate the roof opening panel. A new roof
opening panel motor/module is installed as an assembly.
The roof opening panel motor/module receives voltage from the accessory delay relay through circuit CBP41
(BU) when the key is in the ACC or RUN position and voltage at all times through circuit SBB64 (VT/RD).
Ground is provided to the roof opening panel motor/module and roof opening panel control switch through
circuit GD138 (BK/WH). When the roof opening panel slide switch is pulled, a ground signal is sent to the
roof opening panel motor/module through circuit CPR40 (YE/OG), which causes the roof opening panel to
close. When the roof opening panel slide switch is pressed, a ground signal is sent to the roof opening panel
motor/module through circuit CPR39 (VT/WH), which causes the roof opening panel to open. When the roof
opening panel tilt switch is pressed, a ground signal is sent to the roof opening panel motor/module through
circuit CPR31 (VT/BN), which causes the roof opening panel to open to the VENT position.

Roof opening panel switch
PINPOINT TEST F: THE ROOF OPENING PANEL DOES NOT OPEN OR CLOSE IN VENT POSITION

F1 CHECK THE MOTOR/MODULE

FOR INITIALIZATION
Yes
Attempt to carry out the roof The system is operating normally at this time. The roof
opening panel motor initialization opening panel motor was not initialized.
procedure. Refer to Roof Opening
Panel Motor Initialization in this No
section. GO to F2 .
Was the roof opening panel
initialization procedure
successful?
F2 CHECK THE ROOF OPENING
PANEL SWITCH
Yes
Disconnect: Roof Opening Panel
Switch C930. No
Carry out the roof opening panel INSTALL a new roof opening panel switch. TEST the
switch component test. system for normal operation.
Refer to Wiring Diagrams Cell 149

for component testing.
Is the roof opening panel switch
OK?
F3 CHECK CIRCUIT CPR40 (YE/OG)
FOR AN OPEN
Yes
Disconnect: Roof Opening Panel CHECK the roof opening panel motor/module jumper
Motor/Module In-Line C922. harness for loose pins or an open in circuit CPR40 (YE/OG)
Measure the resistance between between roof opening panel motor/module in-line C922,
roof opening panel switch C930-8, component side, and roof opening panel motor/module
circuit CPR40 (YE/OG), and roof C921, harness side. If the roof opening panel motor/module
opening panel motor/module in-line jumper harness is not OK, INSTALL a new roof opening
C922-6, circuit CPR40 (YE/OG), panel motor/module jumper harness and TEST the system
harness side. for normal operation. If the roof opening panel
motor/module jumper harness is OK, GO to F4 .
No

ohms?
F4 CHECK CIRCUIT CPR31 (VT/BN)
FOR AN OPEN
895
Measure the resistance between Yes

overhead console C930-3, circuit CHECK the roof opening panel motor/module jumper
CPR31 (VT/BN), and roof opening harness for loose pins or an open in circuit CPR40 (YE/OG)
panel motor/module in-line C922-7, between roof opening panel motor/module in-line C922,
circuit CPR31 (VT/BN), harness component side, and roof opening panel motor/module
side. C921, harness side. If the roof opening panel motor/module
jumper harness is not OK, INSTALL a new roof opening
panel motor/module jumper harness and TEST the system
for normal operation. If the roof opening panel
motor/module jumper harness is OK, GO to F5 .
No

ohms?
F5 CHECK THE ROOF OPENING
PANEL MOTOR/MODULE FOR
CORRECT OPERATION
Yes
Disconnect all roof opening panel INSTALL a new roof opening panel motor/module. REFER
motor/module connectors. to Roof Opening Panel Motor in this section. TEST the
Check for: system for normal operation.
corrosion.
bent pins. No
pushed-out pins. The system is operating correctly at this time. Concern may
Connect all roof opening panel have been caused by a loose or corroded connector. TEST
motor/module connectors and make the system for normal operation.
sure they seat correctly.
896
897
Roof Opening Panel Motor Initialization
WARNING: Keep objects and body parts clear of the glass panel when carrying out the
initialization procedure. During the initialization procedure, the glass panel closes with high force and
cannot detect objects in its path. Failure to follow this instruction may result in serious personal injury.
NOTE: A new roof opening panel motor will only open and must be initialized.
NOTE: The roof opening panel motor initialization procedure must be done when repairs are carried out on
any part of the roof opening panel system, including: any time the roof opening panel motor has been
removed from the roof opening panel assembly, a new roof opening panel motor has been installed or when a
new roof opening panel assembly has been installed.
1. Turn the ignition to the RUN position.

For an existing roof opening panel motor, skip to Step 3.
For a new roof opening panel motor, proceed to Step 2.
2. NOTE: If the slide switch is released before initialization movements are complete, turn the ignition
key to the OFF position, then back to the RUN position and repeat this step.
For a new roof opening panel motor/module:
Press the slide switch until the roof opening panel moves past the full OPEN position and
continue to hold for approximately 10 seconds. The roof opening panel will cycle slightly
rearward and then slightly forward to the stored OPEN position.
Quickly release and re-press and hold the slide switch. The roof opening panel glass will
move to the full VENT position, then back to CLOSED (initialization movements). The
initialization movements will start within approximately 3 seconds after the switch is pressed.
When the initialization movements are complete, go to Step 4.
3. NOTE: All roof opening panel motor/module assemblies have an electronically controlled comfort
stop position, which is approximately 50 mm (2 in) from the full OPEN position. When the roof
opening panel is opened, the slide switch must be released when the comfort stop position has been
reached and then pressed again to fully open the roof opening panel.
NOTE: If the slide switch is released before initialization movements are complete, turn the ignition
key to the OFF position, then back to the RUN position, and repeat this step.
For an existing roof opening panel motor/module:
Press and hold the slide switch until the roof opening panel glass moves to the full OPEN
position. Release the switch.
Press and hold the slide switch for approximately 10 seconds. The roof opening panel will
cycle slightly rearward and then slightly forward to the stored OPEN position.
Quickly release and re-press and hold the slide switch. The roof opening panel glass will
move to full VENT position, then back to CLOSED (initialization movements). The
initialization movements will start within approximately 3 seconds after the switch is pressed.
4. Release the slide switch and test the system for normal operation by carrying out one-touch open,
one-touch close and one-touch vent operations.
Roof Opening Panel Motor Initialization 898

Roof Opening Panel Motor Initialization 899

Roof Opening Panel Alignment
NOTE: The roof opening panel motor must be initialized when repairs are carried out on any part of the roof
opening panel, including: whenever the roof opening panel motor has been removed from the roof opening
panel assembly, a new roof opening panel motor has been installed or when a new roof opening panel
assembly has been installed. For additional information, refer to Roof Opening Panel Motor Initialization in
this section.
1. Position the roof opening panel in the CLOSED position.
2. Loosen the 4 roof opening panel glass screws.
3. NOTE: Make sure the roof opening panel is centered in the roof opening.
Adjust the roof opening panel glass height to specification.
4. Maintain horizontal and vertical roof opening panel position while adjusting and tighten the 4 roof
opening panel glass screws to 4 Nm (35 lb-in).
5. Initialize the roof opening panel motor. For additional information, refer to Roof Opening Panel
Roof Opening Panel Alignment 900

Roof Opening Panel Alignment 901

Roof Opening Panel - Exploded View

1 502F24 Roof opening panel glass screw (4 required)
2 500A18 Roof opening panel glass
3 51884 Roof opening panel glass seal
4 15C682 Roof opening panel motor screw (3 required)
5 15790 Roof opening panel motor
6 519A02 Roof opening panel shield
7 502C52 Roof opening panel front drain hose (2 required)
8 502C52 Roof opening panel rear drain hose (2 required)
9 N808401 Roof opening panel frame bolt (9 required)
10 502F36 Air deflector screw (2 required)
11 500A26 Air deflector
12 502F36 Trough assembly screw (2 required)
13 54022 Trough assembly
14 500A65 LH trough guide (RH trough guide part 78500A64)
15 502C22 Roof opening panel frame
17 50152 Roof opening panel shield guide feet (4 required)
Roof Opening Panel - Exploded View 902

Roof Opening Panel - Exploded View 903

Roof Opening Panel Glass
NOTE: The roof opening panel motor must be initialized when repairs are carried out on any part of the roof
opening panel, including: whenever the roof opening panel motor has been removed from the roof opening
panel assembly, a new roof opening panel motor has been installed or when a new roof opening panel frame
has been installed. For additional information, refer to Roof Opening Panel Motor Initialization in this section.
1. NOTE: The roof opening panel glass must be in the CLOSED position.
Remove the 4 roof opening panel glass screws.
2. Remove the roof opening panel glass.

Align the roof opening panel. For additional information, refer to Roof Opening Panel
Initialize the roof opening panel motor. For additional information, refer to Roof Opening
Panel Motor Initialization in this section.
Roof Opening Panel Glass 904

Roof Opening Panel Rear Trough Guide
NOTE: The roof opening panel must be initialized when repairs are carried out on any part of the roof
opening panel, including: whenever the roof opening panel has been removed from the roof opening panel
assembly, a new roof opening panel motor/module has been installed or when a new roof opening panel
this section.
1. Remove the roof opening panel glass. For additional information, refer to Roof Opening Panel Glass
in this section.
2. Remove the 2 trough guide retaining screws and the trough from the trough guide assembly.
3. Disconnect the trough guide rods from the lifter arm assemblies.
4. Position the glass frame to the VENT position.
5. Slide the trough guide back to the slot (approximately 15 mm [0.6 in]) cut in track.
Pull the front of the guide up.
Holding the guide rod, gently rock the guide side to side while pulling the guide forward until
the guide is fully out of the track.
6. Inspect the trough guide assembly for damage. If damage is found, inspect the track for broken pieces
and remove them.
Roof Opening Panel Rear Trough Guide 905


Roof Opening Panel Rear Trough Guide 906

Air Deflector
1. Open the roof opening panel.
2. NOTE: RH side shown, LH side similar.
Remove the 2 plastic air deflector screws.
3. NOTE: When the roof opening panel is removed from the tracks, inspect the tracks for any remaining
guides.
Raise the front of the air deflector.
4. Slide the air deflector toward the rear, then lift up to release it from the pivot shafts.
Air Deflector 907

Air Deflector 908

Roof Opening Panel Shield
this section.
in this section.
2. Remove the water trough.

1. Remove the 2 screws.
2. Remove the water trough.
3. NOTE: When the roof opening panel is removed from the tracks, inspect the tracks for any remaining
guides.
Flex the opening shield to remove the guides from the tracks and remove the roof opening panel
shield.

Roof Opening Panel Shield 909

Roof Opening Panel Shield 910

Roof Opening Panel Weatherstrip
Removal
this section.
in this section.
2. Place roof opening panel, topside up, on a worktable. Take care to support the glass assembly from
below to prevent damaging the mounting tabs.
3. Remove the old roof opening panel weatherstrip by pulling up on the weatherstrip.
Installation
1. Place a new weatherstrip into position on the glass assembly, with the splice (seam) on the passenger
side.
2. Starting with the corners, push the weatherstrip into position. Continue pushing the weatherstrip into
position around the glass assembly until complete. Use a plastic or rubber hammer if necessary.
3. Install the roof opening panel. For additional information, refer to Roof Opening Panel Glass in this
section.
4. Align the roof panel. For additional information, refer to Roof Opening Panel Alignment in this
section.
5. Initialize the roof opening panel motor. For additional information, refer to Roof Opening Panel
Roof Opening Panel Weatherstrip 911

Roof Opening Panel Weatherstrip 912

Roof Opening Panel Motor
Removal
this section.
1. Remove the headliner. For additional information, refer to Section 501-05 .
2. Disconnect the roof opening panel motor electrical connector.
3. Remove the roof opening panel motor.

Installation
1. Connect the roof opening panel motor electrical connector.
2. NOTE: When installing the roof opening panel motor/module, align the 3 attach holes before
engaging the drive gear into the roof opening panel drive cable. Do not rotate the motor assembly
after the drive gear is engaged with the roof opening panel drive cable. Otherwise, the cable can bind.
Install the roof opening panel motor.
Align the attach holes, then install the 3 screws and tighten to 4 Nm (35 lb-in).
Roof Opening Panel Motor 913

3. Connect the overhead console electrical connectors.
4. Initialize the roof opening panel motor/module. For additional information, refer to Roof Opening
5. Disconnect the overhead console electrical connectors.
6. Install the headliner. For additional information, refer to Section 501-05 .
Roof Opening Panel Motor 914

Roof Opening Panel Frame
this section.
2. Disconnect the electrical connector and 3 pushpin retainers.

Position the wiring harness aside.
3. Remove the roof opening panel frame.

1. Disconnect the 4 roof opening panel drain hoses.
2. Remove the 9 bolts.
3. Remove the roof opening panel frame.
4. To install, reverse the removal procedure. If a new roof opening panel frame is being installed,
transfer the existing roof opening panel motor, air deflector, rear trough, roof opening panel glass and
roof opening panel shield onto the new frame assembly. Initialize the roof opening panel motor. For
additional information, refer to Roof Opening Panel Motor Initialization in this section.
Roof Opening Panel Frame 915


SECTION 501-19: Bumpers 2011 Expedition, Navigator Workshop Manual


Bumper cover-to-fender bolts 11 - 97
Fender splash shield screws 3 - 27
Front bumper nuts 90 66 -
Grille-to-radiator support bolts 4 - 35
Rear bumper cover nuts and bolts 8 - 71


Bumper - Exploded View, Front

1 W711401 Front fender splash shield screws (4 required)
2 W707522 Front bumper cover-to-fender bolt (4 required)
3 W712336 Grille-to-radiator support bolt (4 required)
4 17D597 Front bumper cover
5 15200 Fog lamp electrical connector
6 17C882 Isolator
7 W710807 Front bumper nut (6 required)
8 17757 Front bumper
Bumper - Exploded View, Front 918

Bumper - Exploded View, Front 919


Bumper Cover - Front
1. Remove the 3 lower air deflector pin-type retainers.

Position the air deflector aside.
2. Remove the 2 front bumper cover lower pin-type retainers.
3. Remove the 4 LH and RH front fender splash shield screws.
4. Remove the 4 LH and RH front bumper cover-to-fender bolts.

5. If equipped, disconnect the fog lamp electrical connector.
6. If equipped, disconnect the park aid sensor electrical connector.
7. Remove the upper air deflector.

Remove the 10 pin-type retainers.
NOTE: Right side shown, left side similar.p>
8. Remove the 2 upper pin-type retainers for the lower air deflector.
Bumper Cover - Front 920

9. Remove the 4 grille-to-radiator support bolts.
10. Remove the front bumper cover.
Bumper Cover - Front 921


Bumper - Front
1. Remove the front bumper cover. For additional information, refer to Bumper Cover - Front in this
section.
2. Remove the front bumper.

Remove the 6 nuts.
Bumper - Front 922


Bumper - Exploded View, Rear

1 W711401 Rear fender splash shield screws (4 required)
2 W708035 Pin-type retainer (2 required)
3 W705132 Rear bumper cover bolts (3 required)
4 17K835 Rear bumper cover
5 17775 Rear bumper
Bumper - Exploded View, Rear 923


Bumper Cover - Rear
1. Remove the 4 LH and RH rear fender splash shield screws.
2. Remove the 4 LH and RH inner bumper cover nuts.
3. If equipped, disconnect the reverse parking aid electrical connector.
4. Remove the 2 rear bumper cover lower pin-type retainers.
5. Remove the rear bumper cover.

Remove the 2 rear bumper cover pin-type retainers and the 3 rear bumper cover bolts.
Bumper Cover - Rear 924


SECTION 501-20A: Safety Belt System 2011 Expedition, Navigator Workshop Manual

Child safety seat tether anchor bolt 15 - 133
Safety belt anchor bolt 40 30 -
Safety belt buckle and pretensioner nut 55 41 -
Safety belt D-ring bolt 40 30 -
Safety belt shoulder height adjuster bolt 40 30 -
Safety belt sling bolt 40 30 -
Second row safety belt buckle bolts 50 37 -
Second row safety belt buckle nut 55 41 -
Third row safety belt buckle bolt 40 30 -

Safety Belt System
WARNING: After any crash, all of the following safety belt assemblies and attaching hardware
must be inspected to verify correct function:
Retractors
Buckles
Belt tension sensor (BTS) (if equipped)
Front safety belt buckle support assemblies (slide bar) (if equipped)
Safety belt shoulder belt height adjusters (if equipped)
Child safety seat tether bracket assemblies
Automatic locking retractor (ALR) feature for child safety seats (passenger seating positions only)
If any safety belt assembly is damaged, does not operate correctly or does not pass all of the Functional Tests
in the Component Tests of this section, a new safety belt assembly must be installed. If any safety belt
assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original structural
integrity and new safety belt assembly and attaching hardware must be installed. Failure to install new safety
belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash.
After any crash that results in deployment of the driver and/or front outboard passenger safety belt
pretensioners, new driver and/or front outboard passenger safety belt systems (including retractors, buckles
and height adjusters) must be installed. Failure to install new safety belt systems increases the risk of serious
The safety belt retractor is designed to let the webbing move freely in and out at all times, except during
vehicle hard braking, hard cornering or an impact of 24 km/h (15 mph) or more, when it is automatically
locked by a mechanically actuated inertia sensor.
When replacing safety belt buckles and/or retractor assemblies, use only the replacement parts specified in the
Ford Catalog AdvantageTM or equivalent.
Active Restraint System Components
The active restraint system consists of the following serviceable items:
Front row safety belt buckle and pretensioners attached to the seat tracks
Front row safety belt shoulder height adjusters attached to the B-pillar sheet metal behind the trim
panels
Front row safety belt retractors attached to the B-pillar sheet metal behind the trim panels
Second row center safety belt buckle attached to the 20 percent seat base
Second row center safety belt retractor attached to the 20 percent seat backrest frame
Second row outboard safety belt buckles attached to the 40 percent seat bases
Second row outboard safety belt retractors attached to the quarter panel sheet metal behind the trim
panels
Third row center child safety seat tether anchor, bolted to the 60 percent seat backrest frame
Third row center safety belt retractor attached to the 60 percent seat backrest frame
Third row LH and center safety belt buckle assembly attached to the floor pan under the 60 percent
seat
Third row outboard safety belt retractors attached to the D-pillar sheet metal behind the trim panels
Third row RH safety belt buckle attached to the 40 percent seat cushion frame
Safety Belt System 927

Safety Belt Buckles
Safety Belt Buckle and Pretensioner
The safety belt buckle and pretensioner is a pyrotechnic device that removes excess webbing from the front
seat safety belt system. When the front air bag system is deployed, the pretensioner in the buckle deploys,
causing the buckle to move downward, pulling excess webbing from the lap and shoulder safety belts.
If the vehicle is involved in a collision that results in deployment of the front air bags and safety belt
pretensioners, the driver and passenger sea belt system (including safety belt buckle and pretensioners, safety
belt retractors and shoulder height adjusters) must be replaced.
For safety belt buckle pretensioner diagnosis and disposal information, refer to Section 501-20B .
Rear Safety Belt Buckles
The second row seat safety belt buckles and third row RH safety belt buckle are attached to the seat frames.
The third row LH and center safety belt buckle assembly is attached to the floor pan underneath the 60 percent
seat. All rear safety belt buckles are serviceable separately.
Safety Belt Retractors
The safety belt retractors are a dual locking mode type and consist of the following features:
Emergency Locking Retractor (ELR)

Automatic Locking Retractor (ALR) (all except driver seat)
Safety Belt Retractor and Features
Emergency Locking Retractor (ELR)
The ELR is a vehicle sensitive feature designed to activate and lock the safety belt webbing when braking
hard, cornering hard or in an impact of approximately 24 km/h (15 mph). The ELR feature helps to reduce the
forward movement of the occupants. For testing, refer to the appropriate Functional Test procedure in Safety
Belt System in this section.
Automatic Locking Retractor (ALR)
The ALR mode is used when locking a child seat in an outboard seating position. The ALR mode is
automatically activated when the safety belt webbing is fully extracted from the retractor and then allowed to
retract. As the safety belt webbing is retracted back onto the spool, an audible clicking sound is made
indicating the safety belt retractor is in ALR mode and the safety belt webbing will not pull back out of the
safety belt retractor. To disengage the ALR mode, allow the safety belt webbing to fully retract back onto the
spool. The ALR mode is disengaged when the webbing is free to extract and retract back into the retractor.
When installing a dual locking mode retractor, the retractor should be checked to make sure it is not in the
ALR mode after installation in the stowed position. Refer to the appropriate Functional Test procedure in
Safety Belt System in this section.
Child Safety Seat Restraints
The child safety seat restraints include the following items:
Emergency Locking Retractor (ELR) 928

Non-serviceable second row child safety seat tether anchors welded to the seat cushion frames of the
20 and 40 percent seats
Non-serviceable second row lower anchors and tethers for children welded to the seat cushion frames
of the 20 and 40 percent seats
Third row center child safety seat tether anchor, bolted to the 60 percent seat backrest frame
If a child safety seat was in use during a collision, inspect the child safety seat component mounting areas and
repair any damage and restore the vehicle to the original production configuration.
For removal and installation of child safety seat tether anchor, refer to the appropriate procedure in this
section or Section 501-10 for seat cushion frame replacement.
Automatic Locking Retractor (ALR) 929

Safety Belt System
Retractors
Buckles
Safety Belt Warning System
The driver safety belt warning indicator illuminates and a chime sounds to remind the occupants to fasten
their safety belts.
The conditions of operation for the driver safety belt warning indicator and chime are as follows:
If the driver safety belt is not buckled before the ignition switch is turned to ON, then the safety belt
warning indicator illuminates for 1 to 2 minutes and the warning chime sounds for 4 to 8 seconds.
If the driver safety belt is buckled while the warning indicator is illuminated and the warning chime is
sounding, then the safety belt warning indicator and warning chime turn off.
If the driver safety belt is buckled before the ignition switch is turned to ON, the safety belt warning
indicator and warning chime will remain off.
Belt-Minder
The Belt-Minder feature is a supplemental warning to the safety belt warning function. This feature provides
an additional reminder to the driver that the driver safety belt is unbuckled by intermittently sounding a chime
and illuminating the safety belt warning indicator in the Instrument Cluster (IC).
When a MyKeyTM is in the ignition, deactivation of Belt-Minder will be ignored. The Belt-Minder
feature can be activated or deactivated by the administrator key. Using the non-administrator key will override

the deactivation of the Belt-Minder feature. Refer to Section 419-01B or the Owner's Literature for further
information on MyKeyTM functionality.
To activate or deactivate the Belt-Minder feature, refer to Section 413-01 or the Owner's Literature.
If... Then...
the driver's safety belt is not buckled the Belt-Minder feature is activated - the safety belt warning
approximately 5 seconds after the safety indicator illuminates and the warning chime sounds for 6
belt warning indicator has turned off... seconds every 30 seconds, repeating for approximately 5
minutes or until the safety belt is buckled.
the driver's safety belt is buckled while the the Belt-Minder feature will not activate.
safety belt warning indicator is illuminated
and the safety belt warning chime is
sounding...
the driver's safety belt is fore the ignition the Belt-Minder feature will not activate.
switch is turned to the ON position...
1. Verify the customer's concern by operating the active restraint system to duplicate the condition.
2. Inspect to determine if any of the following mechanical or electrical concerns apply:
Cut, frayed or incorrectly routed safety belt Bare, broken or disconnected wire
webbing Connector not tightly engaged
Safety belt buckle and tongue assembly Safety belt warning indicator burned out or
Safety belt retractor broken
3. If the inspection reveals an obvious concern(s) that can be readily identified, service as required. With
the exception of removing a twist from the safety belt webbing, do not attempt to repair a component
of the safety belt system; new components must be installed.
4. If the concern remains after the inspection, determine the symptom. GO to Symptom Chart .
5. To check the active restraint system for correct operation, carry out the appropriate Functional Test(s).
&nbs;
Symptom Chart

Symptom Chart
Component Test
Retractors
Buckles
Carry out the appropriate Functional Test(s) as determined in Inspection and Verification.
Functional Test - Safety Belt Buckle and Tongue
The safety belt buckle and tongue assembly must operate freely during the latching and unlatching function.
Fasten the safety belt by inserting the tongue (male portion) into the buckle (female portion).
1. Verify the following during the latching sequence:

Tongue insertion is not hindered by excessive effort.
A click is heard when the safety belt buckle latches the tongue.
2. Verify the system integrity by forcefully pulling on the safety belt webbing.
3. Unlatch the safety belt by fully depressing the safety belt buckle release button and allowing the
safety belt to release and retract.
4. Verify the following during the unlatching process:

Push-button depression does not require excessive effort.
The tongue can be removed easily from the buckle.
5. Repeat the above steps 3 times.
6. If the functional test reveals a concern(s), install a new safety belt buckle or safety belt retractor as
required.
Functional Test - Safety Belt Retractor

The safety belt retractor must be freely operational for extraction and retraction of the safety belt webbing
between full extension and in-vehicle stowed positions.
1. Extract and retract the safety belt between the full extension and stowed positions.
2. Verify the safety belt retractor operates without excessive effort or binding.
3. Install a new safety belt retractor if any concern is found or the complaint has been verified.
Functional Test - Safety Belt Retractor, Automatic Locking Retractor (ALR) Mode p>
1. Position the seat backrest fully upright (if adjustable).
2. Position the safety belt shoulder height adjuster (if equipped) in the full down or up position.
3. Fasten the safety belt.
4. Pull out the safety belt webbing until the ALR feature is activated.
5. Allow the safety belt webbing to retract until it stops.
6. Pull on the safety belt webbing to check that the safety belt retractor has remained in the ALR mode.
If the safety belt retractor is not locked, install a new safety belt retractor.
7. Unfasten the safety belt and allow the safety belt webbing to retract to its stowed position.
8. Pull out and retract the safety belt webbing to verify the safety belt retractor has converted
automatically out of ALR mode. If the safety belt retractor remains locked in the ALR mode, install a
new safety belt retractor.
Functional Test - Safety Belt Retractor, Road Test Inspection
WARNING: The driver and passenger must be prepared to brace themselves in the event the
safetyelt retractor does not lock. Failure to follow this instruction may result in serious personal injury.
NOTE: Make sure there is no excessive slack in the safety belt webbing across the torso during testing.
NOTE: Do not jerk on the safety belt webbing when carrying out this test.
1. Test the safety belts in the following sequence:

1. Fasten the safety belts and proceed to a safe area.
2. Attain a speed of 24 km/h (15 mph).
3. WARNING: Apply maximum brake force only on dry concrete or equivalent hard
surface, NEVER on wet pavement or gravel. Failure to follow this instruction may
Grasp the shoulder harness, lean forward and apply the brakes, making a maximum braking
application without a skid.
4. The safety belts should lock up with minimum webbing extension.
5. If there is a lockup of all safety belt retractors being tested, the safety belt retractors are
functioning correctly. If any safety belt retractor fails to lock up, install a new safety belt
retractor(s).


Safety Belt Maintenance
Retractors
Buckles
1. The safety belt assemblies should be periodically inspected to make sure that they have not become
damaged and that they remain in correct operating condition, particularly if they have been subjected
to severe stress.
2. Before installing the new safety belt assembly, the safety belt retaining areas must be inspected for
damage and distortion. If the retaining points are damaged and distorted, the sheet metal must be
reworked back to its original shape and structural integrity.
3. Install the new safety belt(s) using the appropriate instructions. Carry out the appropriate Functional
Test Procedure. For additional information, refer to the appropriate Functional Test procedure in
Safety Belt System , Component Test, in this section.
Safety Belt Maintenance 935

Safety Belt Maintenance 936

Safety Belt Procedure After a Collision
Retractors
Buckles
1. Before installing a new safety belt assembly, the safety belt attaching areas must be inspected for
damage and distortion. If the attaching points are damaged and distorted, the sheet metal must be
worked back to its original shape and structural integrity.
2. Install the new safety belt(s). For additional information, refer to the appropriate procedure in this
section. Carry out all applicable Functional Tests for the component(s). For additional information,
refer to the appropriate Functional Test procedure in Safety Belt System in this section.
Safety Belt Procedure After a Collision 937

Safety Belt Procedure After a Collision 938

Safety Belt Twisted at the Safety Belt Guide - Outboard
NOTE: Typical D-ring shown, others similar.
1. Grasp the belt webbing at the shoulder belt guide (D-ring).
2. Rotate and fold the belt webbing over itself to remove the twist.
3. Feed the folded portion of the belt through the safety belt guide (D-ring).
Safety Belt Twisted at the Safety Belt Guide - Outboard 939

Safety Belt Cleaning
WARNING: Do not bleach or re-dye the safety belt webbing, as the webbing may weaken. Failure to
follow this instruction may increase the risk of serious personal injury or death in a crash.
1. Clean the safety belt webbing only with a mild soap solution recommended for carpet and upholstery
cleaning. Follow the instructions provided with the soap.
Safety Belt Cleaning 940

Safety Belt Tongue Rotated on Belt
1. Fold the safety belt as indicated.
2. Pull the safety belt tongue over the fold in the safety belt.
Safety Belt Tongue Rotated on Belt 941

Safety Belt Retractor - Front

1 611B08 RH/ 611B09 Safety belt retractor
LH
2 N807750 Safety belt retractor bolt (part of 611B08 RH/
611B09 LH)
3 - Safety belt guide (part of 611B08 RH/ 611B09
LH)
4 - D-ring bolt (part of 611B08 RH/ 611B09 LH)
5 7860626 D-ring front cover
6 - D-ring inner cover (part of service kit 7860262)
7 - D-ring outer cover (part of service kit 7860262)
Retractors
Buckles
Front safety belt buckle support assemblie) (if equipped)
Safety Belt Retractor - Front 942

1. NOTE: Inspect the D-ring cover for damage. If the cover is damaged or does not remain closed,
install a new D-ring cover.
Remove the upper and lower B-pillar trim panels. For additional information, refer to Section 501-05 .
2. Release the 2 pin-type retainers and safety belt guide.
3. Remove the bolt and safety belt retractor.

NOTE: Remove the shipping clip after safety belt retractor installation.
5. Check the active restraint system for correct operation. For additional information, refer to the
appropriate Functional Test in Safety Belt System in this section.
Safety Belt Retractor - Front 943

Safety Belt Retractor - Second Row and Third Row, Outboard
Expedition/Navigator

1 611B68 Second row safety belt retractor
2 N807750 Second row safety belt retractor bolt
3 W704947 Second row D-ring bolt
4 N808774 Second row safety belt anchor bolt
5 611B68 Third row safety belt retractor
6 - Third row D-ring cover
7 - Third row D-ring bolt
8 N808774 Third row safety belt retractor bolt
Safety Belt Retractor - Second Row and Third Row, Outboard 944
Item Part Number

1 611B68 Second row safety belt retractor
2 611B68 Third row safety belt retractor
3 N807750 Second row safety belt retractor bolt
4 N807750 Third row safety belt retractor bolt
5 W713146 Safety belt sling bolt
6 4060262 Sling bolt cover
Retractors
Buckles
All retractors
Expedition EL/Navigator L 945

Second row retractors
install a new D-ring cover and bolt.
Open the D-ring cover and remove the D-ring bolt.

Third row retractors
install a new D-ring cover and bolt. Expedition and Navigator third row D-ring cover is serviced as
part of the safety belt retractor assembly.
If equipped, open the D-ring cover and remove the D-ring bolt.
5. If equipped, remove the sling bolt cover and safety belt sling bolt.
6. For RH third row safety belt retractor, remove the 2 screws and position aside the auxiliary relay box,
if equipped.
All retractors
7. Remove the bolt and safety belt retractor.

NOTE: Before installing the third row safety belt anchor, make sure the floor-slotted plastic insert is
still present. If it is not, another insert must be installed.


Safety Belt Retractor - Second Row, Center

1 611D52 Safety belt retractor cover foam
2 W504042 Safety belt retractor cover screws (2 required)
4 - Safety belt retractor guide (part of 611B64)
Retractors
Buckles
Automatic locking retractor (ALRure for child safety seats (passenger seating positions only)
Safety Belt Retractor - Second Row, Center 948

NOTE: The retractor may be equipped with an additional web stop button (small, thin, round button, not to be
confused with the larger web stop button) located on the safety belt webbing. This button is only used for
vehicle assembly and serves no other functional purpose. The button can possibly be retracted under the trim
bezel, making it difficult to pull the safety belt webbing out of the retractor. To service, remove this web stop
button. Do not install a new safety belt retractor to eliminate this condition. Any resulting appearance
concerns with the webbing can be worked out by hand. For additional information, refer to Safety Belt System
in this section.
1. Remove the second row 20 percent seat backrest trim cover. For additional information, refer to
Section 501-10 .
2. Remove the seat backrest foam pad.
3. Remove the safety belt retractor cover foam.
4. Remove the 2 screws from the seat belt retractor cover and remove the cover.

6. Pinch and release the safety belt retractor guide from the seat backrest frame and remove the safety
belt retractor.


Safety Belt Retractor - Third Row, Center

1 W708687 Safety belt retractor cover screws (4 required)
5 - Safety belt retractor guide (part of 611B64)
6 - Safety belt retractor insulator (part of 611B64)
Retractors
Buckles
Automatic locking retALR) feature for child safety seats (passenger seating positions only)
Safety Belt Retractor - Third Row, Center 951

NOTE: The retractor may be equipped with an additional web stop button (small, thin, round button, not to be
confused with the larger web stop button) located on the safety belt webbing. This button is only used for
vehicle assembly and serves no other functional purpose. The button can possibly be retracted under the trim
bezel, making it difficult to pull the safety belt webbing out of the retractor. To service, remove this web stop
button. Do not install a new safety belt retractor to eliminate this condition. Any resulting appearance
concerns with the webbing can be worked out by hand.
1. Remove the third row 60 percent seat backrest trim cover. For additional information, refer to Section
501-10 .
2. Remove the seat backrest foam pad.
3. Remove the 4 screws from the safety belt retractor cover (2 shown).

5. Pinch to release the safety belt retractor guide and remove the safety belt retractor.


Safety Belt Shoulder Height Adjuster

1 - Height adjuster cover (part of 602B82)
2 - Height adjuster bolt (part of 602B82)
3 602B82 Height adjuster
4 - D-ring bolt (part of 611B08 RH/ 611B09 LH)
5 7860626 D-ring front cover
6 - D-ring inner cover (part of service kit 7860262)
7 - D-ring outer cover (part of service kit 7860262)
Retractors
Buckles
belt assemblies and atrdware may increase the risk of serious personal injury or death in a crash.
Safety Belt Shoulder Height Adjuster 954

install a new D-ring cover.
Remove the upper B-pillar trim panel. For additional information, refer to Section 501-05 .
2. Access the bolt behind the safety belt shoulder height adjuster cover in the following sequence:
1. Lower the safety belt shoulder height adjuster to the lowest point.
2. Fold the cover over.
3. Remove the safety belt shoulder height adjuster bolt.

4. Remove the safety belt shoulder height adjuster in the following sequence:
1. Rotate the safety belt shoulder height adjuster downward to release the lower tab.
2. Remove the safety belt shoulder height adjuster.
Safety Belt Shoulder Height Adjuster 955

Safety Belt Buckle - Second Row, 20 Percent Seat

1 60044 Safety belt buckle assembly
2 N620483 Safety belt buckle nut
Retractors
Buckles
assembly attaching areas are damaged or distorted, the sheet metal must be restored ts original structural
1. Position the seat upright.
2. Remove the nut and safety belt buckle from underneath the seat.
3. NOTE: When installing the safety belt buckle, make sure to engage the anti-rotation tab to the seat
frame.
Safety Belt Buckle - Second Row, 20 Percent Seat 956


Safety Belt Buckle - Second Row, 40 Percent Seat

1 666L76 Side shield
2 613D98 Safety belt buckle
3 - Safety belt buckle bolt (part of 613D98)
Retractors
Buckles
in the Component Tests of this section, a new safety belt ay must be installed. If any safety belt assembly
attaching areas are damaged or distorted, the sheet metal must be restored to its original structural integrity
and new safety belt assembly and attaching hardware must be installed. Failure to install new safety belt
assemblies and attaching hardware may increase the risk of serious personal injury or death in a crash.
1. Pivot the 40 percent seat upward.
2. Remove the rearward screw (not shown) and seat side shield.
Release the pin-type retainer (not shown).

3. Remove the bolt and safety belt buckle.


Safety Belt Buckle - Third Row, 40 Percent Seat

1 60044 Safety belt buckle
2 N807750 Safety belt buckle bolt
Retractors
Buckles
assembly attaching areas are damaged or distorted, the sheet metal must be restored to its oril structural
1. Remove the third row 40 percent seat. For additional information, refer to Section 501-10 .
2. Remove the bolt and safety belt buckle.

Safety Belt Buckle - Third Row, 40 Percent Seat 960


Safety Belt Buckle - Third Row, 60 Percent Seat

1 60044 Safety belt buckle assembly
2 N807750 Safety belt buckle bolt
Retractors
Buckles
assembly attaching areas are damaged or distorted, the sheet metal must be restored ts original structural
1. Fold the 60 percent seat down.
2. Position the load floor panels up.
3. Remove the bolt and safety belt buckle assembly.


4. Fold the 60 percent seat up and remove the safety belt buckle assembly through the seat.

Safety Belt Buckle and Pretensioner

1 61202 Safety belt buckle and pretensioner
2 - Safety belt buckle switch electrical connector
3 - Safety belt pretensioner electrical connector
4 N800937 Safety belt buckle and pretensioner nut
WARNING: To reduce the risk of accidental deployment, do not use any memory saver devices.
Failure to follow this instruction may result in serious personal injury or death.
Retractors
Buckles
assembly attaching areas are damaged or distorted, the sheet metal must be restored to its original
structuintegrity and new safety belt assembly and attaching hardware must be installed. Failure to install new
safety belt assemblies and attaching hardware may increase the risk of serious personal injury or death in a
crash.
Safety Belt Buckle and Pretensioner 964

WARNING: Never disassemble or tamper with safety belt buckle/retractor pretensioners or

adaptive load limiting retractors or probe the electrical connectors. Failure to follow this instruction
may result in the accidental deployment of the safety belt pretensioners or adaptive load limiting
retractors which increases the risk of serious personal injury or death.
removed and the ignition switch is ON.
1. Remove the 40 percent front seat. For additional information, refer to Section 501-10 .
2. Release the hook-and-loop strip and pull the seat cushion trim cover up enough to expose the safety
belt buckle and pretensioner.
3. NOTE: Make note of the wire harness routing for installation.
Remove the tie strap from the pretensioner.
Disconnect the safety belt buckle switch electrical connector.

Disconnect the safety belt buckle pretensioner electrical connector.
4. Remove the nut and safety belt buckle and pretensioner.

6. Install the 40 percent front seat. For additional information, refer to Section 501-10 .


Child Safety Seat Tether Anchor
Retractors
Buckles
1. Position the third row seat backrest downward.
2. Release the seat backrest cover J-clips.
3. With the seat backrest cover and cushion positioned aside, remove the bolt and the child safety seat
tether anchor.
4. WARNING: Always tighten the child safety seat tether anchor/bolt to specification. Failure
to follow this instruction may result in the child's safety seat being incorrectly secured, which
Child Safety Seat Tether Anchor 967

increases the risk of serious personal injury or death to the child in a sudden stop or crash.
NOTE: Inspect the seat for damage. If the seat is found to be damaged, install new seat components.

SECTION 501-20B: Supplemental Restraint System 2011 Expedition, Navigator Workshop Manual

C-pillar side impact sensor bolt 11 - 97
Front door side impact sensor bolts 3 - 27
Front impact severity sensor bolt 11 - 97
Passenger air bag module bolts 9 - 80
Restraints Control Module (RCM) bolts 11 - 97
Safety Canopy module front tether cord bracket bolt 6 - 53
Safety Canopy module bolts 9 - 80
Second row safety belt retractor anchor bolt 40 30 -
Second row safety belt retractor D-ring 40 30 -
Side air bag module nuts 10 - 89
Steering column manual tilt lever 6 53

Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
The Supplemental Restraint System (SRS) is designed to provide increased collision protection for front seat
and second row outboard occupants in addition to that provided by the 3-point safety belt system. Safety belt
use is necessary to obtain the best occupant protection and to receive the full advantage of the SRS .
The serviceable SRS components are shown in the following illustration.
Supplemental Restraint System (SRS) Components
Part
1 044A74 Passenger air bag module assembly
2 04338 Passenger air bag cover
3 14B345 First row, passenger side impact sensor (pressure sensor,
located in passenger door)
4 61202 Passenger safety belt buckle and pretensioner (includes
safety belt buckle switch)
5 611D10 Passenger seat side air bag module
6 61203 Driver safety belt buckle and pretensioner (includes
safety belt buckle switch)
7 14B345 Second row, passenger side impact sensor (C-pillar)
8 042D95 Driver side Safety Canopy module
8 042D94 Passenger side Safety Canopy module
9 14B345 Second row, driver side impact sensor (C-pillar)
10 611D10 Driver seat side air bag module
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) 970
11 14B345 First row, driver side impact sensor (pressure sensor,

located in the driver door)
12 14B416 Driver seat track position sensor
13 043B13 Driver air bag module
14 14A664 Clockspring
15 14B321 Restraints Control Module (RCM)
16 14B345 Front impact severity sensor
Supplemental Restraint System (SRS) Components 971

Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS)
Special Tool(s)
Flex Probe Kit



The Restraints Control Module (RCM) continuously receives/monitors all inputs from the following
Supplemental Restraint System (SRS) components:
Front impact severity sensor

Driver and passenger front door side impact sensors
Driver and passenger C-pillar side impact sensors
Safety belt buckle switches (driver and passenger)
Driver seat track position sensor
If the RCM detects sudden vehicle deceleration and/or lateral deceleration based on information received from
sensors and switches and determines that deployment is required, the RCM sends voltage and current to
deploy the appropriate SRS components.
The RCM contains an internal sensor that detects vehicle rollover angles. If the RCM determines that a
rollover condition exists and deployment is required, the RCM deploys the applicable SRS components.
During a frontal or side crash, the RCM may deploy the following SRS components, based on crash severity
and sensor input.
Safety belt buckle pretensioner(s)

Safety Canopy
Seat side air bag(s)
Driver and passenger dual-stage air bags (one or both stages)
The fact that the safety belt bucle pretensioner(s), safety belt retractor(s) or air bags did not activate for both
front seat occupants in a crash does not mean that something is wrong with the SRS system.
The RCM carries out a self-test of the complete SRS during each startup. During normal operation, the
Instrument Cluster (IC) illuminates the air bag warning indicator continuously for 6 seconds. If the SRS is
free of faults, the air bag warning indicator turns off and remains off. If a SRS fault exists, the air bag warning
indicator illuminates and remains illuminated for the rest of the ignition cycle. In addition to the self-test at
start up, the RCM continuously monitors all of its SRS components and circuitry for correct operation.
Air Bag Module Second Stage Deployment Check
Because the driver and passenger front air bags each have 2 deployment stages, it is possible that stage 1 has
deployed and stage 2 has not.
If a front air bag module has deployed, the front air bag module must be remotely deployed using the
appropriate air bag disposal procedure.
For information on driver air bag module and/or passenger air bag module remote deployment, refer
to Pyrotechnic Device Disposal in this section.
Air Bag Warning Indicator
The air bag warning indicator:
is located in the IC and proves out by lighting for 6 seconds and then turns off.
flashes and/or illuminates based on the message the IC receives from the RCM .
illuminates if the IC does not receive a message from the RCM .
Clockspring
The clockspring is mounted on the steering column, behind the steering wheel and allow for continuous
electrical connections between the driver air bag module and the RCM while the steering wheel turns.
Driver Air Bag Module
The driver air bag module is a dual-stage air bag. Upon receiving a flow of current from the RCM , it deploys
at 1 of 2 different rates depending upon vehicle impact severity and sensor input.
Event Notification Signal
The purpose of the deployment event notification feature is to provide other vehicle subsystems with
information pertaining to restraint system deployment or fuel cutoff status. Signal communication between the
RCM and fuel pump control module allows the PCM to initiate fuel cut-off to disable the fuel system in the
event of a crash.
The RCM does not monitor the event notification signal circuit faults and does not set a DTC if a fault
occurs.
High Speed Controller Area Network (HS-CAN)
This vehicle utilizes a communication system called a High Speed Controller Area Network (HS-CAN). The
RCM communicates with various modules for required information about the vehicle. For information about
the HS-CAN , refer to Section 418-00 .
Impact Sensors
For this vehicle, the SRS uses 5 satellite sensors in addition to the RCM . The RCM is mounted to the center
tunnel. All vehicles have one front impact severity sensor located in the front-center area of the vehicle,
behind the bumper mounted on the lower radiator support. The first row impact sensors (pressure-based
sensors) are located in each of the front doors behind the trim panel, the second row sensors are located on
each C-pillar. The side impact sensors are not interchangeable between the first and second row. Mounting
orientation is critical for correct operation of all impact sensors.
Passenger Air Bag Module
The passenger air bag module is a dual-stage air bag, deploying at 1 of 2 different rates depending upon
vehicle impact severity and sensor input. It cannot be interchanged between Expedition and Navigator
vehicles.
Restraints Control Module (RCM)
in a crash.
NOTICE: Prior to the installation of a new Restraints Control Module (RCM), it is necessary to upload
module configuration information to the scan tool. This information needs to be downloaded into the
new RCM once installed. Refer to Section 418-01 /a>.
NOTE: This vehicle may be equipped with the SYNC feature which contains the 911 assist option. Refer to
the Owner's Literature.
NOTE: Carrying out Programmable Module Installation (PMI) does not enable the 911 assist option that is
disabled. The RCM and Accessory Protocol Interface Module (APIM) must be configured correctly to fully
support 911 assist functionality.
NOTE: When a new PCM is installed, the air bag warning indicator will illuminate when the ignition switch
is ON. The warning indicator will remain on until PCM configuration is restored. Clear the RCM DTCs.
The RCM carries out the following functions:
Deploys the air bag(s)/Safety Canopy in the event of a deployable crash

Activates the safety belt buckle pretensioners to remove slack from the safety belt in the event of a
crash
Activates the driver and passenger retractor to control the tension of the driver and passenger safety
belts in the event of a crash
Monitors the SRS for ults
Sends a message to the IC to illuminate the air bag warning indicator if a fault is detected
The RCM monitors the SRS for possible faults. If a fault is detected, the RCM requests the IC to illuminate
the air bag warning indicator. When the ignition is turned OFF and then ON, the IC proves out the air bag
warning indicator by lighting for 6 seconds. If no faults are detected by the RCM , the IC turns the air bag
warning indicator off and it remains off. If the RCM detects a fault, it sends a message to the IC to turn the air
bag warning indicator on and it remains on for the rest of the ignition cycle. If the RCM requests illumination
of the air bag warning indicator and the air bag warning indicator does not function, the IC automatically
activates an audible chime.
The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air
bags in the event that the ignition circuit is lost or damaged during impact. The backup power supply depletes
its stored energy approximately one minute after power and/or ground is removed from the RCM .
Safety Belt Buckle Pretensioners
The safety belt buckle pretensioners remove excess slack from the safety belt webbing. The pretensioners are
activated by the RCM when the module detects a crash event force exceeding a programmed limit.
Safety Belt Buckle Switches
The safety belt buckles are comprised of integrated circuits called Hall-effect switches. The safety belt buckle
switches indicate to the RCM whether the safety belts are buckled or unbuckled.
The RCM also communicates the driver safety belt buckle switch status to the IC , which monitors the
information to control the safety belt warning indicator. For information on the safety belt warning indicator,
Safety Canopy Module
and new A-, B-, C- and D-pillar upper trim panels and attaching hardware must be installed. Remove
any other damaged components and hardware and install new components and hardware as needed.
Failure to follow these instructions may result in the Safety Canopy or side air curtain module
deploying incorrectly and increases the risk of serious personal injury or death in a crash.
The Safety Canopy module:
deploys upon receiving a flow of current from the RCM , initiaby the RCM .
is mounted above the headliner.
attaches from the A-pillar frame to the D-pillar frame.
Seat Side Air Bag Module
The side air bag module:
deploys upon receiving a flow of current from the RCM , initiated by the RCM .
is mounted in the seat backrest.
is used in conjunction with a Safety Canopy module.
Seat Track Position Sensor
The seat track position sensor indicates to the RCM the position of the driver seat along the seat track . The
sensor detects the presence of a shunt bracket on the track, indicating that the seat has moved forward beyond
a certain point of adjustment. The RCM uses this information (and other information) in determining the
deployment rate of the dual-stage driver air bag module.
Secondary Air Bag Warning (Chime)
The secondary air bag warning chime is an audible chime located in and controlled by the IC . Ifa fault is
detected with the air bag warning indicator, a DTC is stored in the IC memory. Upon receiving the message
from the RCM that a SRS fault has been detected, the IC sounds the secondary air bag warning chime in a
pattern of 5 sets of 5 beeps.
1. Verify the customer concern by checking the air bag warning indicator in the Instrument Cluster (IC).
Refer to Prove Out the System in this section.
2. Visually inspect for obvious signs of mechanical or electrical damage. Do not disconnect electrical
connectors until directed to do so within the pinpoint test.
Damaged Restraints Control Module (RCM) or Open Smart Junction Box (SJB) fuse 32
loose mounting (10A)
Damaged front impact severity sensor or loose Damaged wiring harness
mounting Loose, damaged or corroded connectors
Damaged side impact sensor, front door and/or Circuitry open/shorted
C-pillar Damaged shorting bars
Damaged front driver/passenger seat assembly Loose, damaged or pinched passenger seat
wire harness


verify the ignition is ON.

418-00 .
If the network test passes, retrieve and record on-demand and Continuous Memory
Diagnostic Trouble Codes (CMDTCs) from the RCM .
8. If the DTCs retrieved are related to the concern, go to the Restraints Control Module (RCM) DTC
Chart. For all other DTCs, refer to Section 419-10 .
DTC Charts
The DTCs can be retrieved from the Restraints Control Module (RCM) with a scan tool via the Data Link
Connector (DLC).
Restraints Control Module (RCM) DTC Chart
NOTE: Always make sure the correct Supplemental Restraint System (SRS) component is being installed.
Parts released for other vehicles may not be compatible even if they appear physically similar. Check the part
number listed in the Ford Catalog AdvantageTM or equivalent to make sure the correct component is being
installed. If an incorrect SRS component is installed, DTCs may set.
NOTE: Network DTCs (U-codes) are often a result of intermittent concerns such as damaged wiring or low
battery voltage occurrences. Additionally, vehicle repair procedures such as module reprogramming often set
network DTCs. Replacing a module to resolve a network DTC Is unlikely to resolve the concern. To prevent
repeat network DTC concerns, Inspect all network wiring, especially connectors. Test the vehicle battery,
NOTE: This module utilizes a 5-character DTC followed by a 2-character failure type code. The failure type
code provides information about specific fault conditions such as opens or shorts to ground. Continuous
Memory Diagnostic Trouble Codes (CMDTCs) have an additional 2-character DTC status code suffix to
assist in determining DTC history.
DTC Description Action To Take

B0001:11 Driver Frontal Stage 1 GO to Pinpoint Test A .
Deployment Control: Circuit
Short to Ground
Short to Battery
Open
B0001:1A Driver Frontal Stage 1 GO to Pinpoint Test A .

Resistance Below Threshold
B0001:2B Driver Frontal Stage 1 GO to Pinpoint Test Q .
Deployment Control: Signal
Cross Coupled
B0001:4A Driver Frontal Stage 1 GO to Pinpoint Test R .
Deployment Control:
Incorrect Component
Installed
B0002:11 Driver Frontal Stage 2 GO to Pinpoint Test B .
Short to Ground
Short to Battery
Open
B0002:1A Driver Frontal Stage 2 GO to Pinpoint Test B .
B0002:2B Driver Frontal Stage 2 GO to Pinpoint Test Q .
Cross Coupled
B0002:4A Driver Frontal Stage 2 GO to Pinpoint Test R .
Deployment Control:
Incorrect Component
Installed
B0010:11 Passenger Frontal Stage 1 GO to Pinpoint Test C .
Short to Ground
Short to Battery
Open
B0010:1A Passenger Frontal Stage 1 GO to Pinpoint Test C .
B0010:2B Passenger Frontal Stage 1 GO to Pinpoint Test Q .
Cross Coupled
B0010:4A Passenger Frontal Stage 1 GO to Pinpoint Test R .
Deployment Control:
Incorrect Component
Installed
B0011:11 Passenger Frontal Stage 2 GO to Pinpoint Test D .
Short to Ground

Short to Battery
Open
B0011:1A Passenger Frontal Stage 2 GO to Pinpoint Test D .
B0011:2B Passenger Frontal Stage 2 GO to Pinpoint Test Q .
Cross Coupled
B0011:4A Passenger Frontal Stage 2 GO to Pinpoint Test R .
Deployment Control:
Incorrect Component
Installed
B0020:11 Left Side Airbag Deployment GO to Pinpoint Test E .
Control: Circuit Short to
Ground
Battery
Control: Circuit Open
B0020:1A Left Side Airbag Deployment GO to Pinpoint Test E .
Control: Circuit Resistance
Below Threshold
B0020:2B Left Side Airbag Deployment GO to Pinpoint Test Q .
Control: Signal Cross
Coupled
B0020:4A Left Side Airbag Deployment GO to Pinpoint Test R .
Control: Incorrect Component
Installed
B0021:11 Left Curtain Deployment GO to Pinpoint Test F .
Control 1: Circuit Short to
Ground
Battery
Control 1: Circuit Open
B0021:1A Left Curtain Deployment GO to Pinpoint Test F .
Control 1: Circuit Resistance
Below Threshold
B0021:2B Left Curtain Deployment GO to Pinpoint Test Q .
Control 1: Signal Cross
Coupled
B0021:4A Left Curtain Deployment GO to Pinpoint Test R .
Control 1: Incorrect
Component Installed
B0028:11 Right Side Airbag GO to Pinpoint Test G .

Short to Ground
Short to Battery
Open
B0028:1A Right Side Airbag GO to Pinpoint Test G .
B0028:2B Right Side Airbag GO to Pinpoint Test Q .
Cross Coupled
B0028:4A Right Side Airbag GO to Pinpoint Test R .
Deployment Control:
Incorrect Component
Installed
B0029:11 Right Curtain Deployment GO to Pinpoint Test H .
Ground
Battery
Control 1: Circuit Open
B0029:1A Right Curtain Deployment GO to Pinpoint Test H .
Control 1: Circuit Resistance
Below Threshold
B0029:2B Right Curtain Deployment GO to Pinpoint Test Q .
Control 1: Signal Cross
Coupled
B0029:4A Right Curtain Deployment GO to Pinpoint Test R .
Control 1: Incorrect
Component Installed
B0050:11 Driver Seatbelt Sensor: GO to Pinpoint Test I .
Circuit Open
B0050:1D Driver Seatbelt Sensor: GO to Pinpoint Test I .
Circuit Current Out of Range
B0050:2B Driver Seatbelt Sensor: Signal GO to Pinpoint Test Q .
Cross Coupled
B0050:4A Driver Seatbelt Sensor: GO to Pinpoint Test R .
Incorrect Component
Installed
B0052:11 GO to Pinpoint Test J .
Passenger Seatbelt Sensor:

B0052:12 Passenger Seatbelt Sensor: GO to Pinpoint Test J .
B0052:13 Passenger Seatbelt Sensor: GO to Pinpoint Test J .
Circuit Open
B0052:1D Passenger Seatbelt Sensor: GO to Pinpoint Test J .
Circuit Current Out of Range
B0052:2B Passenger Seatbelt Sensor: GO to Pinpoint Test Q .
Signal Cross Coupled
B0052:4A Passenger Seatbelt Sensor: GO to Pinpoint Test R .
Incorrect Component
Installed
B0090:11 Left Frontal Restraints GO to Pinpoint Test K .
Sensor: Circuit Short to
Ground
B0090:4A Left Frontal Restraints GO to Pinpoint Test R .
Sensor: Incorrect Component
Installed
B0090:81 Left Frontal Restraints INSTALL a new front impact severity sensor. REFER to Front
Sensor: Invalid Serial Data Impact Severity Sensor in this section.
Received
B0090:93 Left Frontal Restraints GO to Pinpoint Test K .
Sensor: No Operation
B0090:96 Left Frontal Restraints INSTALL a new front impact severity sensor. REFER to Front
Sensor: Component Internal Impact Severity Sensor in this section.
Failure
B0091:11 Left Side Restraints Sensor 1: GO to Pinpoint Test L .
B0091:4A Left Side Restraints Sensor 1: GO to Pinpoint Test R .
Incorrect Component
Installed
B0091:81 Left Side Restraints Sensor 1: INSTALL a new driver door side impact sensor. REFER to Side
Invalid Serial Data Received Impact Sensor - Front Door in this section.
B0091:93 Left Side Restraints Sensor 1: GO to Pinpoint Test L .
No Operation
B0091:96 Left Side Restraints Sensor 1: INSTALL a new driver door side impact sensor. REFER to Side
Component Internal Failure Impact Sensor - Front Door in this section.
B0092:11 Left Side Restraints Sensor 2: .
B0092:4A Left Side Restraints Sensor 2: GO to Pinpoint Test R .
Incorrect Component
Installed
B0092:81 Left Side Restraints Sensor 2: INSTALL a new driver C-pillar side impact sensor. REFER to
Invalid Serial Data Received Side Impact Sensor - C-Pillar in this section.
B0092:93 Left Side Restraints Sensor 2: GO to Pinpoint Test M .
No Operation
B0092:96 Left Side Restraints Sensor 2: INSTALL a new driver C-pillar side impact sensor. REFER to
Component Internal Failure Side Impact Sensor - C-Pillar in this section.
B0096:11 Right Side Restraints Sensor GO to Pinpoint Test M .

1: Circuit Short to Ground
B0096:4A Right Side Restraints Sensor GO to Pinpoint Test R .
1: Incorrect Component
Installed
B0096:81 Right Side Restraints Sensor INSTALL a new passenger door side impact sensor. REFER to
1: Invalid Serial Data Side Impact Sensor - Front Door in this section.
Received
B0096:93 Right Side Restraints Sensor GO to Pinpoint Test M .
1: No Operation
B0096:96 Right Side Restraints Sensor INSTALL a new passenger door side impact sensor. REFER to
1: Component Internal Failure Side Impact Sensor - Front Door in this section.
B0097:11 Right Side Restraints Sensor GO to Pinpoint Test L .
2: Circuit Short to Ground
B0097:4A Right Side Restraints Sensor GO to Pinpoint Test R .
2: Incorrect Component
Installed
B0097:81 Right Side Restrain Sensor 2: INSTALL a new passenger C-pillar side impact sensor. REFER to
Invalid Serial Data Received Side Impact Sensor - C-Pillar in this section.
B0097:93 Right Side Restraints Sensor GO to Pinpoint Test L .
2: No Operation
B0097:96 Right Side Restraints Sensor INSTALL a new passenger C-pillar side impact sensor. REFER to
2: Component Internal Failure Side Impact Sensor - C-Pillar in this section.
B00B5:11 Driver Seat Track Position GO to Pinpoint Test N .
Restraints Sensor: Circuit
Short to Ground
Short to Battery
Open
B00B5:1D Driver Seat Track Position GO to Pinpoint Test N .
Current Out of Range
B00B5:2B Driver Seat Track Position GO to Pinpoint Test Q .
Restraints Sensor: Signal
Cross Coupled
B00B5:4A Driver Seat Track Position GO to Pinpoint Test R .
Restraints Sensor: Incorrect
Component Installed
B1193:00 Crash Event Storage Full and INSTALL a new Restraints Control Module (RCM) and impact
Locked: No Sub Type sensors. REFER to Inspection and Repair After a Supplemental
Information Restraint System (SRS) Deployment in this section.
B1212:11 Driver Seatbelt Buckle GO to Pinpoint Test O .
Pretensioner Deployment
Ground

Battery
B1212:1A Driver Seatbelt Buckle GO to Pinpoint Test O .
Below Threshold
B1212:2B Driver Seatbelt Buckle GO to Pinpoint Test Q .
Coupled
B1212:4A Driver Seatbelt Buckle GO to Pinpoint Test R .
Installed
B1213:11 Passenger Seatbelt Buckle GO to Pinpoint Test P .
Ground
Battery
B1213:1A Passenger Seatbelt Buckle GO to Pinpoint Test P .
Below Threshold
B1213:2B Passenger Seatbelt Buckle GO to Pinpoint Test Q .
Coupled
B1213:4A Passenger Seatbelt Buckle GO to Pinpoint Test R .
Installed
U0028:08 Vehicle Communication Bus GO to Pinpoint Test S .
A: Bus Signal / Message
Failures
U0028:88 Vehicle Communication Bus GO to Pinpoint Test S .
A: Bus Off
U0100:00 Lost Communication With NOTE: The DTC sets in a module that is reporting a
ECM/PCM "A": No Sub communication fault from another module on the data bus. The
Type Information module that reports the fault is not the problem module. Do not
install a new RCM as part of repair.
REFER to Section 418-00 to diagnose the no communication with

the PCM.
U0155:00 Lost Communication With NOTE: The DTC sets in a module that is reporting a
Instrument Panel Cluster communication fault from another module on the data bus. The
(IPC) Control Module: No module that reports the fault is not the problem module. Do not
Sub Type Information install a new RCM as part of repair.
REFER to Section 418-00 to diagnose the no communication with

the Instrument Cluster (IC) module.
U0253:00 Lost Communication With NOTE: This DTC sets in the RCM if a message is not received
Accessory Protocol Interface from the Accessory Protocol Interface Module (APIM).
Module: No Sub Type
Information CHECK for additional RCM and APIM DTCs.
REFER to the appropriate section to diagnose the DTCs. If no

other DTCs are present, REFER to Accessory Protocol Interface
Module (APIM) Software Level Check in the General Procedures
portion of Section 415-00 .
U0300:00 Internal Control Module CARRY OUT Programmable Module Installation (PMI).
Software Incompatibility: No
Sub Type Information RETRIEVE RCM DTCs.
If RCM DTC U0300:00 is retrieved on-demand during self-test,

INSTALL a new RCM . REFER to Restraints Control Module
(RCM) in this section.
U0401:00 Invalid Data Received From CARRY OUT a self-test of the PCM and diagnose any DTCs
ECM/PCM "A": No Sub present. REFER to the Powertrain Control/Emissions Diagnosis
Type Information (PC/ED) manual or the Diagnostic Trouble Code (DTC) Chart in
Section 303-14 .
U0554:00 Invalid Data Received From CHECK for additional RCM and APIM DTCs.
Accessory Protocol Interface
Module: No Sub Type REFER to the appropriate section to diagnose the DTCs. If no
Information other DTCs are present, REFER to Accessory Protocol Interface
Module (APIM) Software Level Check in the General Procedures
portion of Section 415-00 .
U2100:00 Initial Configuration Not CARRY OUT Programmable Module Installation (PMI).
Complete: No Sub Type RETRIEVE RCM DTCs. If RCM DTC U2100:00 is retrieved,
Information INSTALL a new RCM . REFER to Restraints Control Module
(RCM) in this section.
U2200:00 Control Module INSTALL a new RCM and CARRY OUT Programmable Module
Configuration Memory Installation (PMI). Use as-built data when CARRYING out PMI
Corrupt: No Sub Type for this DTC. REFER to Restraints Control Module (RCM) in this
Information section.
U3000:46 Control Module: Calibration / INSTALL a new RCM . REFER to Restraints Control Module
Parameter Memory Failure (RCM) in this section.
U3000:49 Control Module: Internal INSTALL a new RCM and CARRY OUT Programmable Module
Electronic Failure Installation (PMI). If DTC U2200:00 is also present, use as-built
data when CARRYING out PMI . REFER to Restraints Control
Module (RCM) in this section.
U3000:4A Control Module: Incorrect GO to Pinpoint Test R .
Component Installed
U3002:62
Vehicle Identification CARRY OUT PMI . REFER to Section 418-00 .

Number: Signal Compare
Failure If the DTC is retrieved a second time, INSTALL a new RCM .
REFER to Restraints Control Module (RCM) in this section.
U3003:16 Battery Voltage: Circuit GO to Pinpoint Test T .
Voltage Below Threshold
U3003:17 Battery Voltage: Circuit GO to Pinpoint Test T .
Voltage Above Threshold
Symptom Chart
Symptom Chart
Pinpoint Test - Restraints Control Module (RCM)
Pinpoint Test A: DTCs B0001:11, B0001:12, B0001:13 and B0001:1A
Refer to Wiring Diagrams Cell 46 , Supplemental Restraint System for schematic and connector information.
Normal Operation
The Restraints Control Module (RCM) continuously monitors the driver air bag module stage 1 circuits for
the following faults:
Resistance out of range

Unexpected voltage
Short to ground
Faulted driver air bag module
If a fault is detected, the RCM stores DTC B0001:11, B0001:12, B0001:13 or B0001:1A in memory and
sends a message to the Instrument Cluster (IC) to illuminate the air bag warning indicator.
The RCM analyzes the deployment loop resistance to determine if a fault exists. The value displayed in the
PID is the deployment loop resistance measured by the RCM . If the value displayed is lower or higher than
the desired range (refer to diagram below), the RCM can set a DTC. As the deployment loop resistance drifts
farther outside the desired range, the chance for a DTC increases. Small variations in resistance can occur due
to the effect of road vibrations on terminal fit. Crimps and terminals can be affected by stress and harness
movement and can cause an increase in resistance due to wire strain. These variables can result in an
intermittent fault. For this reason, the test requires the PID value to be within the desired range before the fault
is considered repaired, regardless if the module is reporting an on-demand DTC at the time of diagnosis.
Following this direction helps make sure that minor changes in resistance do not create a repeat concern. This
test uses process of elimination to diagnose each part of the deployment loop circuit including:
Wiring
Connections
Clockspring
Driver air bag module
RCM

DTC Description Fault Trigger Condition

A fault is indicated when the RCM senses a short to ground
B0001:11 - Driver Frontal Stage 1 on either driver air bag stage 1 circuit.
Deployment Control: Circuit Short to
Ground
A fault is indicated when the RCM senses a short to voltage
Battery
A fault is indicated when the RCM measures more than the
B0001:13 - Driver Frontal Stage 1 desired resistance range between driver air bag stage 1
Deployment Control: Circuit Open circuits.
A fault is indicated when the RCM measures less than the
B0001:1A - Driver Frontal Stage 1 desired resistance range between driver air bag stage 1
Deployment Control: Circuit Resistance circuits.
Below Threshold
PINPOINT TEST A: DTCs B0001:11, B0001:12, B0001:13 AND B0001:1A
verification before proceeding with the pinpoint test. /p>
NOTE: Only disconnect or reconnect Supplemental Restraint System (SRS) components when
instructed to do so within a pinpoint test step. Failure to follow this instruction may result in incorrect
diagnosis of the SRS .
NOTE: Always make sure the correct SRS component is being installed. Parts released for other vehicles
may not be compatible even if they appear physically similar. Check the part number listed in the Ford
Catalog AdvantageTM or equivalent to make sure the correct component is being installed. If an incorrect
SRS component is installed, DTCs may set.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer.
NOTE: During testing, wire color may change as they pass through connectors.
PINPOINT TEST A: DTCs B0001:11, B0001:12, B0001:13 AND B0001:1A 986


A1 RETRIEVE RCM DTCs
Yes
Ignition ON. This fault cannot be cleared
Enter the following diagnostic mode on the scan tool: Self Test - until it is corrected and the
RCM . DTC is no longer retrieved
Was DTC B0001:11, B0001:12, B0001:13 or B0001:1A on-demand during self-test.
retrieved on-demand during self-test?
For DTC B0001:13 or
B0001:1A, GO to A2 .
For DTC B0001:11, GO to

A12 .

A15 .
No
This is an intermittent fault
when present as a Continuous
Memory Diagnostic Trouble
Code (CMDTC) only.
For DTC B0001:13 or

B0001:1A, GO to A20 .

A21 .

A22 .
A2 CHECK THE DRIVER FRONTAL STAGE 1 DEPLOYMENT
CONTROL RESISTANCE (DEPLOY_00_R) PID
Yes
DataLogger - RCM .
DEPLOY_00_R PID No
Does the PID value read between 2 and 3.68 ohms? GO to A3 .
CONTROL RESISTANCE (DEPLOY_00_R) PID WHILE
CARRYING OUT THE HARNESS TEST
Yes
While monitoring the DEPLOY_00_R PID, carry out the harness DEPOWER the SRS and
test of the driver air bag circuits and accessible connectors REPAIR the connector,
(including any in-line connectors) by wiggling and flexing the terminals or wire harness or
wire harness, connectors, tilting and rotating the steering wheel INSTALL a new clockspring
frequently. as needed. REFER to
Does the PID value read between 2 and 3.68 ohms while Clockspring in this section.
carrying out the harness test?
Refer to Wiring Diagrams Cell
5 , Connector Repair
Procedures for schematic and
connector information.

GO to A24 .
No
For PID value less than 2
ohms, GO to A4 .
For PID value greater than

3.68 ohms, GO to A8 .
CONTROL DTC FOR A FAULT STATUS CHANGE (LOW
RESISTANCE INDICATED)
Yes
NOTE: This pinpoint test step attempts to change the fault GO to A17 .
reported by the RCM by inducing a different fault condition. If
the reported fault changes, this indicates the RCM is functioning No
correctly and is not the source of the fault. GO to A5 .
Ignition OFF.
(SRS) Depowering and Repowering in this section.
Remove the driver air bag module. Refer to Driver Air Bag
Module in this section.
Repower the SRS . Do not prove out the SRS at this time. Refer
to Supplemental Restraint System (SRS) Depowering and
Repowering in this section.
Ignition ON.
Enter the following diagnostic mode on the scan tool: Self Test -
RCM .
DIAGNOSTIC TIP: When viewing DTCs with the driver air
bag module disconnected, open circuit faults are normally
retrieved on stages 1 and 2.
Did the on-demand DTC change from B0001:1A to
B0001:13?
RESISTANCE INDICATED) (CLOCKSPRING DISCONNECTED)
Yes
the reported fault changes, this indicates the RCM is functioning No
Ignition OFF.
Disconnect: Clockspring C218A.
Ignition ON.
RCM .
bag module / clockspring disconnected, open circuit faults are
normally retrieved on stages 1 and 2.
Did the on-demand DTC change from B0001:1A to
B0001:13?

A6 CHECK FOR A SHORT BETWEEN DRIVER AIR BAG

STAGE 1 CIRCUITS
Yes
Measure the resistance between clockspring C218A-1, circuit GO to A7 .
CR101 (VT/BN), harness side and C218A-9, circuit RR101
(YE/GN), harness side. No
REPAIR circuits CR101
(VT/BN) and RR101
(YE/GN).

5 for schematic and connector
information.
GO to A24 .
A7 CHECK THE RCM FOR LOW RESISTANCE
Yes
Ignition OFF. REPAIR circuits CR101
Depower the SRS . Refer to Supplemental Restraint System (VT/BN) and RR101 (YE/GN)
(SRS) Depowering and Repowering in this section. for a short together.
Disconnect: RCM C310A and C310B.
Measure the resistance between RCM C310A pins 3 and 4, Refer to Wiring Diagrams Cell
component side. 5 for schematic and connector
information.
GO to A24 .
No
GO to A19 .

A8 CHECK THE DRIVER AIR BAG STAGE 1 CIRCUITS FOR
AN OPEN
Yes
(SRS) Depowering and Repowering in this section. No
Remove the driver air bag module. Refer to Driver Air Bag GO to A9 .
Measure the resistance between RCM C310A, harness side and
driver air bag module stage 1 C216A, harness side, using the
following chart.

RCM Circuit Stage 1

C310A-4 CR101 C216A-1

(VT/BN)/(GY/OG)
C310A-3 RR101 C216A-2
(YE/GN)/(GY/WH)
Are the resistances less than 1 ohm?

AN OPEN (CLOCKSPRING DISCONNECTED)
Yes
Disconnect: Clockspring C218A. GO to A18 .
clockspring C218A, harness side using the following chart. No
REPAIR circuit CR101
(VT/BN) or RR101 (YE/GN).

RCM Circuit Clockspring 5 for schematic and connector
C310A-4 CR101 (VT/BN) C218A-1 information.
C310A-3 RR101 (YE/GN) C218A-9 GO to A24 .
Are the resistances less than 0.5 ohm?

A10 CHECK THE DRIVER FRONTAL STAGE 1
DEPLOYMENT CONTROL DTC FOR A FAULT STATUS
CHANGE (OPEN INDICATED)
Yes
NOTE: This pinpoint test step attempts to change the fault REMOVE the fused jumper
reported by the RCM by inducing a different fault condition. If wire and GO to A17 .
the reported fault changes, this indicates the RCM is functioning
correctly and is not the source of the fault. No
REMOVE the fused jumper
Connect: RCM C310A and C310B. wire and GO to A11 .
Connect a fused jumper wire between driver air bag module
stage 1 C216A-1, circuit CR101 (GY/OG), harness side, and
C216A-2, circuit RR101 (GY/WH), harness side.

Ignition ON.
RCM .
bag stage 1 circuits shorted together, a low resistance fault is
normally retrieved on stage 1. Stage 2 shows an open circuit
fault due to the driver air bag being disconnected.
Was DTC B0001:1A retrieved on-demand during self-test?
AN OPEN (CLOCKSPRING DISCONNECTED)
Yes
Ignition OFF. REMOVE the fused jumper
Depower the SRS . Refer to Supplemental Restraint System wire and GO to A18 .
Disconnect: Clockspring C218A. No
Connect a fused jumper wire between clockspring C218A-1, REMOVE the fused jumper
circuit CR101 (VT/BN), harness side, and C218A-9, circuit wire and GO to A19 .
RR101 (YE/GN), harness side.
Ignition ON.
RCM .
DIAGNOSTIC TIP: When viewing DTCs with the clockspring
stage 1 circuits shorted together, a low resistance fault is
normally retrieved on stage 1. Stage 2 shows an open circuit
fault due to the driver air bag being disconnected.
Was DTC B0001:1A retried on-demand during self-test?
CHANGE (SHORT TO GROUND INDICATED)

NOTE: This pinpoint test step attempts to change the fault Yes
reported by the RCM by inducing a different fault condition. If GO to A17 .
the reported fault changes, this indicates the RCM is functioning
correctly and is not the source of the fault. No
GO to A13 .
Ignition OFF.
Ignition ON.
RCM .
bag module disconnected, open circuit faults are normally
Did the on-demand DTC change from B0001:11 to
B0001:13?
CHANGE (SHORT TO GROUND INDICATED) (CLOCKSPRING
DISCONNECTED)
Yes
the fault reported changes, this indicates the RCM is functioning No
Ignition OFF.
Ignition ON.
RCM .
disconnected, open circuit faults are normally retrieved on driver
air bag stages 1 and 2.
B0001:13?
A SHORT TO GROUND
Yes
(SRS) Depowering and Repowering in this section. No
Disconnect: RCM C310A and C310B. Due to the shorting bar feature
Measure the resistance between clockspring: in the RCM electrical
C218A-1, circuit CR101 (VT/BN), harness side and connector, the fault can exist
ground. in either circuit. Do not
C218A-9, circuit RR101 (YE/GN), harness side and remove or defeat the shorting
ground. bar.


(VT/BN) or RR101 (YE/GN).

5 for schematic and connector
information.
GO to A24 .
CHANGE (SHORT TO BATTERY INDICATED)
(CLOCKSPRING DISCONNECTED)
Yes
the fault reported changes, this indicates the RCM is functioning No
Ignition OFF.
Ignition ON.
RCM .
bag module/clockspring disconnected, open circuit faults are
normally retrieved on driver air bag stages 1 and 2.
B0001:13?
A SHORT TO VOLTAGE
Yes
Ignition OFF. Due to the shorting bar feature
Depower the S . Refer to Supplemental Restraint System (SRS) in the RCM electrical
Depowering and Repowering in this section. connector, the fault can exist
Disconnect: RCM C310A and C310B. in either circuit. Do not
Repower the SRS . Do not prove out the SRS at this time. Refer remove or defeat the shorting
to Supplemental Restraint System (SRS) Depowering and bar.
Ignition ON. REPAIR circuit CR101
Measure the voltage between clockspring: (VT/BN) or RR101 (YE/GN).
C218A-1, circuit CR101 (VT/BN), harness side and
ground. Refer to Wiring Diagrams Cell
C218A-9, circuit RR101 (YE/GN), harness side and 5 for schematic and connector
ground. information.

GO to A24 .
No
GO to A19 .

A17 CONFIRM THE DRIVER AIR BAG MODULE FAULT
Yes
NOTE: Make sure all restraint system components and the RCM INSTALL a new driver air bag
electrical connectors are connected before carrying out the module. REFER to Driver Air
self-test. If not, DTCs will be recorded. Bag Module in this section.
GO to A24 .
Ignition OFF.
Depower the SRS . Refer to Supplemental Restraint System No
(SRS) Depowering and Repowering in this section. In the process of diagnosing
Install the driver air bag module. Refer to Driver Air Bag the fault, the fault condition
Module in this section. has become intermittent. Do
Repower the SRS . Do not prove out the SRS at this time. Refer not install any new SRS
to Supplemental Restraint System (SRS) Depowering and components at this time.
Repowering in this section. Install SRS components only
Ignition ON. when directed to do so in the
Enter the following diagnostic mode on the scan tool: Self Test - pinpoint test.
RCM .
Was the original DTC retrieved on-demand during self-test? For DTC B0001:13 or
B0001:1A, GO to A20 .

A21 .

A22 .
A18 CONFIRM THE CLOCKSPRING FAULT
Yes
NOTE: Make sure all restraint system components and the RCM INSTALL a new clockspring.
electrical connectors are connected before carrying out the REFER to Clockspring in this
self-test. If not, DTCs will be recorded. section. GO to A24 .
Ignition OFF. No
Depower the SRS . Refer to Supplemental Restraint System In the process of diagnosing
(SRS) Depowering and Repowering in this section. the fault, the fault condition
Prior to reconnecting any previously disconnected SRS has become intermittent. Do
component: not install any new SRS
inspect connector(s) (including any in-line connectors) components at this time.
for pushed-out, loose or spread terminals and loose or Install SRS components only
frayed wire connections at terminals. when directed to do so in the
inspect wire harness for any damaged, pinched, cut or pinpoint test.
pierced wires.
inspect RCM C310A and C310B Connector Position For DTC B0001:13 or
Assurance (CPA) lever/lock for correct operation. Refer B0001:1A, GO to A20 .
to Restraints Control Module (RCM) in this section.

repair any concerns found. For DTC B0001:11, GO to

A21 .
Refer to Wiring Diagrams Cell 5 , Connector Repair
Procedures for schematic and connector information. For DTC B0001:12, GO to
Connect: Clockspring C218A. A22 .
Install the driver air bag module. Refer to Driver Air Bag
Ignition ON.
RCM .
Was the original DTC retrieved on-demand during self-test?
A19 CONFIRM THE RCM FAULT
Yes
NOTE: Make sure all restraint system components and the RCM INSTALL a new RCM .
electrical connectors are connected before carrying out the REFER to Restraints Control
self-test. If not, DTCs will be recorded. Module (RCM) in this section.
GO to A24 .
Ignition OFF.
Depower the SRS . Refer to Supplemental Restraint System No
(SRS) Depowering and Repowering in this section. In the process of diagnosing
Prior to reconnecting any previously disconnected SRS the fault, the fault condition
component: has become intermittent. Do
inspect connector(s) (including any in-line connectors) not install any new SRS
for pushed-out, loose or spread terminals and loose or components at this time.
frayed wire connections at terminals. Install SRS components only
inspect wire harness for any damaged, pinched, cut or when directed to do so in the
pierced wires. pinpoint test.
inspect RCM C310A and C310B Connector Position
Assurance (CPA) lever/lock for correct operation. Refer For DTC B0001:13 or
to Restraints Control Module (RCM) in this section. B0001:1A, GO to A20 .
repair any concerns found.
Refer to Wiring Diagrams Cell 5 , Connector Repair A21 .
Procedures for schematic and connector information.
If previously removed, install the driver air bag module. Refer to For DTC B0001:12, GO to
Driver Air Bag Module in this section. A22 .
Connect: Clockspring C218A (if previously disconnected).
Connect: RCM C310A and C310B.
Ignition ON.
RCM .
Was the original DTC retrieved on-demand during self-test?
DEPLOYMENT CONTROL RESISTANCE (DEPLOY_00_R) PID
FOR AN INTERMITTENT LOW RESISTANCE OR OPEN
CIRCUIT FAULT


DataLogger - RCM . The fault is not present and
DEPLOY_00_R PID cannot be recreated at this
Attempt to recreate the fault by wiggling connectors (including time. Do not install any new
any in-line connectors) and flexing the wire harness, tilting and SRS components at this time.
rotating the steering wheel frequently. Install SRS components only
Does the PID value read between 2 and 3.68 ohms? when directed to do so in the
pinpoint test. GO to A23
No
If the driver air bag PID
indicates incorrect resistance
only when the steering wheel
is rotated, INSTALL a new
clockspring. REFER to
Clockspring in this section.
For all other faults,
DEPOWER the SRS and
REPAIR as necessary.

5 , Connector Repair
Procedures for schematic and
GO to A24 .
DEPLOYMENT CONTROL CIRCUITS FOR AN
INTERMITTENT SHORT TO GROUND FAULT
Yes
Ignition ON. DEPOWER the SRS and
Attempt to recreate the fault by wiggling connectors (including REPAIR as necessary.
any in-line connectors) and flexing the wire harness, tilting and
rotating the steering wheel frequently. Refer to Wiring Diagrams Cell
Enter the following diagnostic mode on the scan tool: Self Test - 5 , Connector Repair
RCM . Procedures for schematic and
Was DTC B0001:11 retrieved on-demand during self-test? connector information.
GO to A24 .
No
The fault is not present and
cannot be recreated at this
time. Do not install any new
SRS components at this time.
Install SRS components only
when directed to do so in the
pinpoint test. GO to A23 .
DEPLOYMENT CONTROL CIRCUITS FOR AN
INTERMITTENT SHORT TO BATTERY FAULT
Yes
Ignition OFF. DEPOWER the SRS and

Depower the SRS . Refer to Supplemental Restraint System Refer to Wiring Diagrams Cell
(SRS) Depowering and Repowering in this section. 5 , Connector Repair
Remove the driver air bag module. Refer to Driver Air Bag Procedures for schematic and
Module in this section. connector information.
to Supplemental Restraint System (SRS) Depowering and GO to A24 .
Ignition ON. No
Attempt to recreate the fault by wiggling connectors (including The fault is not present and
any in-line connectors) and flexing the wire harness, tilting and cannot be recreated at this
rotating the steering wheel frequently. time. Do not install any new
Enter the following diagnostic mode on the scan tool: Self Test - SRS components at this time.
RCM . Install SRS components only
Was DTC B0001:12 retrieved on-demand during self-test? when directed to do so in the
A23 CHECK THE HARNESS AND CONNECTORS
Yes
Ignition OFF. REPAIR as necessary.
(SRS) Depowering and Repowering in this section. Refer to Wiring Diagrams Cell
Remove the driver air bag module: 5 , Connector Repair
inspect connector(s) (including any in-line connectors) Procedures for schematic and
for corrosion, loose or spread terminals and loose or connector information.
frayed wire connections at terminals.
inspect wire harness for any damage, pinched, cut or GO to A24 .
pierced wires.
Inspect RCM C310A and C310B CPA lever/lock for correct No
operation. Refer to Restraints Control Module (RCM) in this The fault is not present and
section. cannot be recreated at this
Were any concerns found? time. Do not install any new
SRS components at this time.
Install SRS components only
when directed to do so in the
A24 CHECK FOR ADDITIONAL SRS DTCs
Yes
Ignition OFF. Do not clear any DTCs until
WARNING: Turn the ignition OFF and wait one minute all DTCs have been resolved.
to deplete the backup power supply. Failure to follow this GO to the DTC Chart in this
instruction may result in serious personal injury or death in section for pinpoint test
the event of an accidental deployment. direction.
Reconnect all SRS components (if previously disconnected).
If previously directed to depower the SRS , repower the SRS . No
Do not prove out the SRS at this time. Refer to Supplemental CLEAR all RCM CMDTCs .
Restraint System (SRS) Depowering and Repowering in this PROVE OUT the SRS . The
section. repair is complete. RETURN
Ignition ON. the vehicle to the customer.
RCM .
Were any RCM DTCs retrieved on-demand during self-test?
Pinpoint Test B: DTCs B0002:11, B0002:12, B0002:13 and B0002:1A

Refer to Wiring Diagrams Cell 46 , Supplemental Restraint System for schematic and connector information.
Normal Operation
The Restraints Control Module (RCM) continuously monitors the driver air bag module stage 2 and circuits
for the following faults:
Resistance out of range

Unexpected voltage
Short to ground
Faulted driver air bag module
If a fault is detected, the RCM stores DTC B0002:11, B0002:12, B0002:13 or B0002:1A in memory and
sends a message to the Instrument Cluster (IC) to illuminate the air bag warning indicator.
The RCM analyzes the deployment loop resistance to determine if a fault exists. The value displayed in the
PID is the deployment loop resistance measured by the RCM . If the value displayed is lower or higher than
the desired range (refer to diagram below), the RCM can set a DTC. As the deployment loop resistance drifts
farther outside the desired range, the chance for a DTC increases. Small variations in resistance can occur due
to the effect of road vibrations on terminal fit. Crimps and terminals can be affected by stress and harness
movement and can cause an increase in resistance due to wire strain. These variables can result in an
intermittent fault. For this reason, the test requires the PID value to be within the desired range before the fault
is considered repaired, regardless if the module is reporting an on-demand DTC at the time of diagnosis.
Following this direction helps make sure that minor changes in resistance do not create a repeat concern. This
test uses process of elimination to diagnose each part of the deployment loop circuit including:
Wiring
Connections
Clockspring
RCM

A fault is indicated when the RCM senses a short to ground
Ground
A fault is indicated when the RCM senses ort to voltage on
B0002:12 - Driver Frontal Stage 2 either driver air bag stage 2 circuit.
Battery
A fault is indicated when the RCM measures more than the
B0002:13 - Driver Frontal Stage 2 desired resistance range between driver air bag stage 2
Deployment Control: Circuit Open circuits.
A fault is indicated when the RCM measures less than the
desired resistance range between driver air bag stage 2

B0002:1A - Driver Frontal Stage 2 circuits.

Deployment Control: Circuit Resistance
Below Threshold

Clockspring
RCM
PINPOINT TEST B: DTCs B0002:11, B0002:12, B0002:13 AND B0002:1A
follow this instruction may result in the accidental deployment of the Sa Canopy and cause serious
NOTE: Only disconnect or reconnect Supplemental Restraint System (SRS) components when
instructed to do so within a pinpoint test step. Failure to follow this instruction may result in incorrect
diagnosis of the SRS .
NOTE: Always make sure the correct SRS component is being installed. Parts released for other vehicles
may not be compatible even if they appear physically similar. Check the part number listed in the Ford
Catalog AdvantageTM or equivalent to make sure the correct component is being installed. If an incorrect
SRS mponent is installed, DTCs may set.
NOTE: During testing, wire color may change as they pass through connectors.

B1 RETRIEVE RCM DTCs
Yes
Ignition ON. This fault cannot be
Enter the following diagnostic mode on the scan tool: Self Test - cleared until it is corrected
RCM . and the DTC is no longer
Was DTC B0002:11, B0002:12, B0002:13 or B0002:1A retrieved retrieved on-demand
on-demand during self-test? during self-test.
For DTC B0002:13 or

B0002:1A, GO to B2 .
PINPOINT TEST B: DTCs B0002:11, B0002:12, B0002:13 AND B0002:1A 999


B11 .

B14 .
No
This is an intermittent fault
when present as a
Continuous Memory
Diagnostic Trouble Code
(CMDTC) only.
For DTC B0002:13 or

B0002:1A, GO to B19 .

B20 .

B21 .
B2 CHECK THE DRIVER FRONTAL STAGE 2 DEPLOYMENT
CONTROL RESISTANCE (DEPLOY_01_R) PID
Yes
Enter the following diagnostic mode on the scan tool: DataLogger - GO to B18 .
RCM .
Does the PID value read between 2 and 3.68 ohms? No
GO to B3 .
CONTROL RESISTANCE (DEPLOY_01_R) PID WHILE
CARRYING OUT THE HARNESS TEST
Yes
While monitoring the DEPLOY_01_R PID, carry out the harness DEPOWER the SRS and
test of the driver air bag circuits and accessible connectors REPAIR the connector,
(including any in-line connectors), by wiggling and flexing the wire terminals or wire harness
harness, connectors, tilting and rotating the steering wheel or INSTALL a new
frequently. clockspring as needed.
Does the PID value read between 2 and 3.68 ohms while REFER to Clockspring in
carrying out the harness test? this section.
Refer to Wiring Diagrams

Cell 5 , Connector Repair
Procedures for schematic
and connector information.
GO to B23 .
No
For PID value less than 2
ohms, GO to B4 .
For PID value greater than

3.68 ohms, GO to B7 .
RESISTANCE INDICATED)
Yes
NOTE: This pinpoint test step attempts to change the fault reported GO to B16 .
by the RCM by inducing a different fault condition. If the reported
fault changes, this indicates the RCM is functioning correctly and is No
not the source of the fault. GO to B5 .
Ignition OFF.
Depower the SRS . Refer to Supplemental Restraint System (SRS)
Depowering and Repowering in this section.
Remove the driver air bag module. Refer to Driver Air Bag Module
in this section.
Repower the SRS . Do not prove out the SRS at this time. Refer to
Supplemental Restraint System (SRS) Depowering and Repowering
in this section.
Ignition ON.
RCM .
DIAGNOSTIC TIP: When viewing DTCs with the driver air bag
module disconnected, open circuit faults are normally retrieved on
stages 1 and 2.
Did the on-demand DTC change from B0002:1A to B0002:13?
RESISTANCE INDICATED) (CLOCKSPRING DISCONNECTED)
Yes
Ignition OFF.
Ignition ON.
RCM .
module/clockspring disconnected, open circuit faults are normally
Did the on-demand DTC change from B0002:1A to B0002:13?
B6 CHECK FOR A SHORT BETWEEN DRIVER AIR BAG STAGE
2 CIRCUITS
Yes
Depowering and Repowering in this section. No
Disconnect: RCM C310A and C310B. REPAIR circuits CR102
Measure the resistance between C218A-2, circuit CR102 (BU), (BU) and RR102 (WH).
harness side and C218A-10, circuit RR102 (WH), harness side.


Cell 5 for schematic and
GO to B23 .

B7 CHECK THE DRIVER AIR BAG STAGE 2 CIRCUITS FOR AN
OPEN
Yes
Remove the driver air bag module. Refer to Driver Air Bag Module GO to B8 .
in this section.
driver air bag module stage 2 C216B, harness side using the
following chart.
RCM Circuit Driver Air Bag Module Stage 2

C310A-7 CR102 (BU)/(YE/WH) C216A-1
C310A-8 RR102 (WH)/(RD/OG) C216A-2
Are the resistances less than 1 ohm?

OPEN (CLOCKSPRING DISCONNECTED)
Yes
Disconnect: Clockspring C218A. GO to B17 .
clockspring C218A, harness side using the following chart. No
(BU) or RR102 (WH).

RCM Circuit Clockspring Cell 5 for schematic and
C310A-7 CR102 (BU) C218A-2 connector information.
C310A-8 RR102 (WH) C218A-10 GO to B23 .

Are the resistances less than 0.5 ohm?

CONTROL DTC FOR A FAULT STATUS CHANGE (OPEN
INDICATED)
Yes
NOTE: This pinpoint test step attempts to change the fault reported REMOVE the fused
by the RCM by inducing a different fault condition. If the reported jumper wire and GO to
fault changes, this indicates the RCM is functioning correctly and is B16 .
not the source of the fault.
No
Connect: RCM C310A and C310B. REMOVE the fused
Connect a fused jumper wire between driver air bag module stage 2 jumper wire and GO to
C216B-1, circuit CR102 (YE/WH), harness side, and C216B-2, B10 .
circuit RR102 (RD/OG), harness side.
in this section.
Ignition ON.
RCM .
DIAGNOSTIC TIP: When viewing DTCs with driver air bag
module stage 2 circuits shorted together, a low resistance fault is
normally retrieved on stage 2. Stage 1 shows an open circuit fault
due to the driver air bag being disconnected.
OPEN (CLOCKSPRING DISCONNECTED)
Yes
Ignition OFF. REMOVE the fused
Depower the SRS . Refer to Supplemental Restraint System (SRS) jumper wire and GO to
Depowering and Repowering in this section. B17 .
Connect a fused jumper wire between clockspring C218A-2, circuit No
CR102 (BU), harness side, and C218A-10, circuit RR102 (WH), REMOVE the fused

harness side. jumper wire and GO to

B18 .
in this section.
Ignition ON.
RCM .
stage 2 circuits shorted together, a low resistance fault is normally
retrieved on stage 2. Stage 1 shows an open circuit fault due to the
driver air bag being disconnected.
CONTROL DTC FOR A FAULT STATUS CHANGE (SHORT TO
GROUND INDICATED)
Yes
in the RCM by inducing a different fault condition. If the reported
Ignition OFF.
in this section.
in this section.
Ignition ON.
RCM .
module disconnected, open circuit faults are normally retrieved on
stages 1 and 2.
Did the on-demand DTC change from B0002:11 to B0002:13?
GROUND INDICATED) (CLOCKSPRING DISCONNECTED)
Yes
fault changes, this indicates the RCM is funioning correctly and is No

Ignition OFF.
Ignition ON.
RCM .
B13 CHECK THE DRIVER AIR BAG STAGE 2 CIRCUITS FOR A
SHORT TO GROUND
Yes
Disconnect: RCM C310A and C310B. REPAIR circuit CR102
Measure the resistance between clockspring: (BU) or RR102 (WH).
C218A-2, circuit CR102 (BU), harness side and ground.
C218A-10, circuit RR102 (WH), harness side and ground. Refer to Wiring Diagrams
Cell 5 for schematic and
GO to B23 .

BATTERY INDICATED) (CLOCKSPRING DISCONNECTED)
Yes
Ignition OFF.
in this section.
in this section.
Ignition ON.
RCM .

Special Tool(s)

Depowering Procedure
1. Turn all vehicle accessories OFF.
2. Turn the ignition switch OFF.
3. At the Smart Junction Box (SJB), located in the RH lower kick panel, remove the cover and the RCM
fuse 32 (10A) from the SJB . For additional information, refer to the Wiring Diagram manual.
4. Turn the ignition switch ON and visually monitor the air bag warning indicator for at least 30
seconds. he air bag warning indicator will remain lit continuously (no flashing) if the correct RCM
fuse has been removed. If the air bag warning indicator does not remain lit continuously, remove the
correct RCM fuse before proceeding.
5. Turn the ignition switch OFF.
6. WARNING: Always deplete the backup power supply before repairing or installing any new
front or side air bag supplemental restraint system (SRS) component and before servicing,
removing, installing, adjusting or striking components near the front or side impact sensors or
Supplemental Restraint System (SRS) Depowering and Repowering 1006

the restraints control module (RCM). Nearby components include doors, instrument panel,
console, door latches, strikers, seats and hood latches. Refer to the Description and Operation
portion of Section 501-20B for location of the RCM and impact sensor(s). To deplete the backup
power supply energy, disconnect the battery ground cable and wait at least 1 minute. Be sure to
disconnect auxiliary batteries and power supplies (if equipped). Failure to follow these
instructions may result in serious personal injury or death in the event of an accidental
deployment.
Disconnect the battery ground cable and wait at least one minute. For additional information, refer to
Section 414-01 .
Repowering Procedure
1. Make sure that all SRS components are connected.
2. Turn the ignition switch from OFF to ON.
3. Install RCM fuse 32 (10A) to the SJB and close the cover.
4. WARNING: Make sure no one is in the vehicle and there is nothing blocking or placed in
front of any air bag module when the battery is connected. Failure to follow these instructions
may result in serious personal injury in the event of an accidental deployment.
Connect the battery ground cable.
5. Prove out the SRS as follows:

Turn the ignition from ON to OFF. Wait 10 seconds, then turn the back to ON and visually monitor
the air bag warning indicator with the air bag modules installed. The air bag warning indicator will
illuminate continuously for approximately 6 seconds and then turn off. If an SRS fault is present, the
air bag warning indicator will:
- fail to light.
- remain lit continuously.
- flash.
The flashing might not occur until approximately 30 seconds after the ignition has been turned from
the OFF to the ON position. This is the time required for the RCM to complete the testing of the SRS
. If the air bag warning indicator is inoperative and a SRS fault exists, a chime will sound in a pattern
of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS fault discovered must be
diagnosed and repaired.
Clear all continuous DTCs from the RCM using a scan tool.


Supplemental Restraint System (SRS) Deactivation and Reactivation
Special Tool(s)

Deactivation
which increases the risk of serious personal injury r death.
2. Make sure the road wheels are in the straight-ahead position.
3. Center the tilt steering column to allow for steering column upper and lower shroud removal.
4. NOTICE: Turn the steering wheel such that the top is at 90 degrees (at the 9 o'clock position) to
the left from the straight-ahead position to access the driver air bag module wire clips and to
prevent damage to the steering column multi-function switch. Failure to follow this instruction
may result in component damage.
Turn the steering wheel so the top of the wheel is 90 degrees to the left (at the 9 o'clock position) as
shown.
Supplemental Restraint System (SRS) Deactivation and Reactivation 1009

5. Remove the lower steering column opening cover.

Pull out to release the top retainers.
Remove the lower steering column opening cover.
If equipped, disconnect the adjustable pedals switch connector.
6. If equipped, remove the screw and steering column manual tilt lever.
7. Remove the 3 steering column lower shroud screws.
8. Release the clips and remove the steering column upper shroud.
9. Remove the steering column lower shroud.

If equipped, disconnect the power tilt steering column switch located on the lower shroud.
10. NOTICE: Make sure each of the 3 driver air bag module wire clips are disengaged from each of
the 3 steering wheel hooks before removing the driver air bag module from the steering wheel.
Failure to follow this instruction may result in component damage and/or system failure.
NOTE: Steering wheel is removed for clarity. The rear of the steering wheel is shown.
NOTE: Use a mirror to view the rear of the steering wheel to locate where the 3 driver air bag
module wire clips attach to the steering wheel hooks.
Using a screwdriver or a suitable tool, release each of the 3 driver air bag module wire clips from the
steering wheel hooks.
Access the 3 driver air bag module wire clips through the back of the steering wheel cover
and push the wire clips toward the center of the steering wheel to release.

11. NOTE: Once the driver air bag module is removed, note the position of the 2 driver air bag module
locator pins on the steering wheel for installation.
Disconnect the driver air bag module and horn switch electrical connectors and remove the driver air
bag module.
12. Turn the steering wheel so the top of the wheel is back in the straight-ahead position (the 12 o'clock
position).
13. Open and lower the glove compartment door to allow access to the passenger air bag electrical
connector.
If equipped, disconnect the glove compartment door dampener.
14. Disconnect the passenger air bag module electrical connector.
15. NOTE: There are 2 similar connectors under the passenger seat. The passenger seat side air bag
module electrical connector is located toward the seat outboard position.
Remove the passenger front seat cushion panel shield and disconnect the passenger seat side air bag
module electrical.

16. Release the RH second row safety belt retractor D-ring cover.
17. Remove the bolt and the RH second row safety belt retractor D-ring.
18. Remove the cover and the RH C-pillar trim panel nut.
19. Release the rear door weatherstrip and remove the RH C-pillar trim panel.
20. Disconnect the RH Safety Canopy module electrical connector.

21. Release the LH second row safety belt retractor D-ring cover.
22. Remoe the bolt and the LH second row safety belt retractor D-ring.
23. Remove the cover and the LH C-pillar trim panel nut.
24. Release the rear door weatherstrip and remove the driver C-pillar trim panel.
25. Disconnect the LH Safety Canopy module electrical connector.
26. NOTE: There are 2 similar connectors under the driver seat. The driver seat side air bag module
electrical connector is located toward the seat outboard position.
Remove the driver front seat cushion panel shield and disconnect the driver seat side ir bag module

27. Install the RCM fuse 32 (10A) to the Smart Junction Box (SJB).
28. Connect the battery ground cable. For additional information, refer to Section 414-01 .
Reactivation
1. Turn the ignition off.
2. Remove the RCM fuse 32 (10A) from the SJB .
3. Disconnect the battery ground cable and wait at least one minute.
4. Connect the driver seat side air bag module electrical connector and install the driver front seat
cushion panel shield.
5. Connect the LH Safety Canopy module electrical connector.
6. Install the LH C-pillar trim panel and attach the rear door weatherstrip.
7. Install the LH C-pillar trim panel nut and cover.

8. Install the LH second row safety belt retractor D-ring and bolt.
9. Attach the LH second row safety belt reractor D-ring cover.

Verify the safety belt retractor operates without excessive effort or binding.
10. Connect the RH Safety Canopy module electrical connector.
11. Install the RH C-pillar trim panel and attach the rear door weatherstrip.
12. Install the passenger C-pillar trim panel nut and cover.

13. Install the RH second row safety belt retractor D-ring and bolt.
14. Attach the RH second row safety belt retractor D-ring cover.
Verify the safety belt retractor operates without excessive effort or binding.
Extract and retract the safety belt between the full extension and stowed positions.
If excessive effort or binding is present, install a new safety belt buckle retractor and
tongue assembly as necessary. For additional information, refer to Section 501-20A .
15. Connect the passenger seat side air bag module electrical connector and install the passenger front
seat cushion panel shield.
16. Connect the passenger air bag module electrical connector.
17. Close the glove compartment door.

If equipped, connect the glove compartment door dampener.

18. NOTICE: The clockspring electrical connectors are unique and cannot be reversed when
connected to the driver air bag module. Match the electrical connector key to the keyway in the
driver air bag module. Do not force the electrical connectors into the driver air bag module.
Damage to the connector or component may occur.
Connect the horn switch and 2 driver air bag module electrical connectors.
19. Position the driver air bag module to the steering wheel, lining up the locator pins.
20. NOTE: Make sure that all 3 driver air bag module wire clips are fully engaged and seated correctly to
the steering wheel.
NOTE: Audible clicks will be heard when the 3 driver air bag module wire clips are fully engaged.
Firmly press the driver air bag module to the steering wheel, seating the 3 driver air bag module wire
clips to the steering wheel hooks.
Check the driver air bag module trim cover to the steering wheel for an even gap clearance
and correct movement.
21. Install the steering column lower shroud.

If equipped, connect the power tilt steering column switch located on the lower shroud.
22. Install the steering column upper shroud.
23. Install the 3 steering column lower shroud screws.
24. If equipped, install the steering column manual tilt lever and screw.
25. If equipped, connect the adjustable pedals switch connector.
26. Install the lower steering column opening cover and 3 screws.

27. Repower and prove out the SRS . For additional information, refer to Supplemental Restraint System

Inspection and Repair After a Supplemental Restraint System (SRS) Deployment
WARNING: Remove restraint system diagnostic tools from the vehicle prior to road testing. If tools
are not removed, the supplemental restraint system (SRS) device may not deploy in a crash. Failure to
follow this instruction may result in serious personal injury or death in a crash and possibly violate
vehicle safety standards.
NOTE: After diagnosing or repairing a SRS , the restraint system diagnostic tools (if required) must be
removed before operating the vehicle over the road.
NOTE: Deployable devices (such as air bag modules, pretensioners) may deploy alone or in various
combinations depending on the impact event.
NOTE: Always refer to the appropriate workshop manual procedures prior to carrying out vehicle repairs
affecting the SRS and safety belt system.
All vehicles
1. NOTE: Refer to the correct removal and installation procedure for all SRS components being
installed.
When any deployable device or combination of devices have deployed and/or the RCM has DTC
B1231/B1193:00 (Event Threshold Exceeded) in memory, the repair of the vehicle SRS is to include
the removal of all deployed devices and the installation of new deployable devices, the removal and
installation of new impact sensors and the removal and installation of a new RCM . DTCs must be
cleared from all required modules after repairs are carried out.
Vehicles with an OCS
2. NOTE: After installation of new OCS components, carry out the OCS Reset procedure as instructed
in the workshop manual. Refer to the appropriate workshop manual for OCS removal and installation
procedure.
When a vehicle has been involved in a collision and the OCSM has DTC B1231/B1193:00 stored in
memory, the repair of the OCS is to include the following procedures for the specified system:
For rail-type OCS , inspect the passenger side floorpan for damage and repair as necessary.
Install new OCS rails. Do not install a new OCSM unless DTC B1231 cannot be cleared.
For weight sensor bolt-type OCS , inspect the passenger side floorpan for damage and repair
as necessary. Install a new seat track with OCS weight sensor bolts. DTC must be cleared
from the OCSM before carrying out OCS Reset. Do not install a new OCSM unless DTC
B1231/B1193:00 cannot be cleared.
For bladder-type OCS , inspect for damage and repair as necessary. If installation of an OCS
component is required, an OCS service kit must be installed.
All vehicles
3. When any damage to the impact sensor mounting points or mounting hardware has occurred, repair or
install new mounting points and mounting hardware as needed.
Inspection and Repair After a Supplemental Restraint System (SRS) Deployment 1019
4. When the driver air bag module has deployed, a new clockspring must be installed.
5. New driver and/or front passenger safety belt systems (including retractors, buckles, anchors and
height adjusters) must be installed if the vehicle is involved in a collision that results in deployment of
the driver and/or front passenger safety belt pretensioners. For additional information, refer to Section
501-20A .
6. Inspect the entire vehicle for damage, including the following components:
Steering column (deployable column if equipped)
Instrument panel knee bolsters and mounting points
Instrument panel braces and brackets
Instrument panel and mounting points
Seats and seat mounting points
Safety belts, safety belt buckles, safety belt retractors and safety belt anchors. For additional
information, refer to Section 501-20A .
SRS wiring, wiring harnesses and connectors
7. After carrying out the review and inspection of the entire vehicle for damage, repair or install new
components as needed.
Inspection and Repair After a Supplemental Restraint System (SRS) Deployment 1020
Pyrotechnic Device Disposal
Disposal of Deployable Devices and Pyrotechnic Devices That are Undeployed/Inoperative
NOTE: All inoperative air bag modules and safety belt pretensioners have been placed on the Mandatory
Return List. All discolored or damaged air bag modules must be treated the same as any inoperative live air
bag being returned.
1. Depower the SRS . Refer to Supplemental Restraint System (SRS) Depowering and Repowering in
the General Procedures portion of this section.
2. Remove the undeployed/inoperative device. Refer to the appropriate procedure in this section or
Section 501-20A .
3. NOTE: When installing a new air bag module or inflatable safety belt inflator, a prepaid return
postcard is provided with the replacement air bag module. The serial number for the new part and the
VIN must be recorded and sent to Ford Motor Company.
If installing a new air bag module or inflatable safety belt inflator, record the necessary information
and return the inoperative air bag module to Ford Motor Company.
Disposal of Deployable Devices and Pyrotechnic Devices That Are Deployed
2. Remove the deployed device. Refer to the appropriate procedure in this section or Section 501-20A .
3. NOTE: If a dual stage driver or passenger air bag module has deployed due to a crash event, the air
bag module requires manual deployment to make sure both stages and the active canister vent have
deployed before scrapping the vehicle or disposing of the air bag module. To determine if a vehicle is
equipped with dual stage driver or passenger air bag modules, refer to the Description and Operation
portion of this section.
Dispose of the deployed device in the same manner as any other part to be scrapped.
Disposal of Deployable Devices and Pyrotechnic Devices That Require Manual Deployment
1. Safety and environmental concerns require consideration and treatment of restraints system
deployable and pyrotechnic devices when disposing of vehicles, deployable devices or pyrotechnic
devices. Deploying deployable and pyrotechnic devices before scrapping a vehicle or the device
eliminates the potential for hazardous exposures or reactions during processing. If special handling
procedures are followed, deployable and pyrotechnic devices can be deployed safely and recycled
with the vehicle, shipped separately to a recycling facility or disposed of safely.
NOTE: To determine the deployable devices a vehicle is equipped with, refer to the Description and
Operation portion of this section.
Pyrotechnic Device Disposal 1021

A vehicle equipped with any of the following deployable devices requires manual deployment of the
devices before scrapping the vehicle or component. Refer to the appropriate portion of this procedure.

Inflatable safety belt inflators
Knee air bag module
Passenger air bag module
Seat side air bag modules
Safety Canopy modules
Side air curtain modules
2. NOTE: To determine the pyrotechnic devices a vehicle is equipped with, refer to the Description and
Operation portion of this section.
A vehicle equipped with any of the following pyrotechnic devices requires manual deployment of the
devices before scrapping the vehicle or component. Refer to the appropriate portion of this procedure.
Safety belt buckle pretensioners

Safety belt retractor pretensioners
Safety belt anchor pretensioners
Adaptive load-limiting retractors
Deployable steering column
3. NOTE: To determine if a vehicle is equipped with dual stage driver or passenger air bag modules,
refer to the Description and Operation portion of this section.
If a dual stage driver or passenger air bag module has deployed due to a crash event, the air bag
module requires manual deployment to make sure both stages and the active canister vent have
deployed before scrapping the vehicle or disposing of the air bag module. Refer to Driver Air Bag
Module, Passenger Air Bag Module, Knee Air Bag Module and Seat Side Air Bag Module - Remote
Deployment in this procedure.
Driver Air Bag Module, Passenger Air Bag Module, Knee Air Bag Module and Seat Side Air Bag
Module - Remote Deployment
WARNING: Always carry or place a live Safety Canopy, or side air curtain module, with the
module and tear seam pointed away from your body. Failure to follow this instruction may result in
serious personal injury or in the event of an accidental deployment.

NOTE: For air bag modules with multiple loops, deploy all of the loops on the air bag module.
NOTE: Some driver and passenger front air bags have 2 deployment stages and an active canister vent. After
a collision it is possible that Stage 1 has deployed and Stage 2 and the active canister vent have not.
If a front air bag module has deployed, it is mandatory that the front air bag module be remotely deployed
using the appropriate air bag disposal procedure.
NOTE: A typical air bag disposal is shown that is similar for all vehicles.
All driver, passenger, knee and seat side air bag modules
1. Make a container to house the air bag module for deployment.

NOTE: The tires must be of sufficient size to accommodate the air bag module.
Obtain a tire and wheel assembly and an additional 4 tires (without wheels) of the same size.
With the tire and wheel assembly on the bottom, stack the tires.
Securely tie all of the tires together.
3. Remove the air bag module. Refer to the appropriate procedure in this section.
4. NOTE: If the air bag module does not have a hard-wired pigtail, cut the wires and connector(s) from
the vehicle wire harness and reconnect to the air bag module.
Cut each of the air bag module wires near the electrical connector that connects to the vehicle wire
harness.
5. Remove any sheathing (if present) and strip the insulation from the ends of the cut wires.
6. NOTE: Typical driver air bag module with 2 loops shown, other air bag modules with multiple loops
or multiple features (canister vent, active tether) similar.
For air bag modules with multiple loops, twist together a wire from each loop then repeat for the
remaining wires from each loop.

7. Make a jumper harness to deploy the air bag module.

Obtain 2 wires (20 gauge minimum) at least 9.14 m (30 ft) long and strip both ends of each
wire.
At one end of the jumper harness, connect the wires together.
8. Using the end of the jumper harness where the wires are not connected together, attach each wire of
the jumper harness to each wire of the air bag module or to the twisted-together wires if multiple
loops. Use tape or other insulating material to make sure that the leads do not make contact with each
other.
Driver air bag modules
9. NOTE: Make sure the air bag connections are maintained.
For driver air bag modules, with the stack of tires upright and the wheel on the bottom, carefully place
the driver air bag module, with the trim cover facing up, on the wheel.
Passenger, knee and seat side air bag modules
10. NOTE: Make sure the air bag connections are maintained.
Tip the stack of tires on its side and place the air bag module inside the center tire, making sure that
there are 2 tires beneath the tire containing the air bag module and 2 tires (including the tire and wheel
assembly) above the tire containing the air bag module.

11. Place the tire stack upright, with the wheel on top.
All driver, passenger, knee and seat side air bag modules
12. Remain at least 9.14 m (30 ft) away from the air bag module.
13. From the end of the jumper harness that is not connected to the air bag module, disconnect the 2 wires
of the jumper harness from each other.
14. Deploy the air bag module by touching the ends of the 2 wires of the jumper harness to the terminals
of a 12-volt battery.
15. To allow for cooling, wait at least 10 minutes before approaching the deployed air bag module.
16. Dispose of the deployed air bag module in the same manner as any other part to be scrapped.
Safety Belt Anchor Pretensioners, Safety Belt Buckle Pretensioners, Safety Belt Retractor
Pretensioners, Adaptive Load Limiting Safety Belt Retractors and Safety Belt Inflators - Remote
Deployment
pretensioners, load limiters and inflators. Ner back probe deployable device electrical connectors.
death.
NOTE: A typical safety belt buckle, retractor and inflator disposal is shown that is similar for all vehicles.
1. Make a container to house the safety belt buckle or retractor for deployment.
NOTE: The tires must be of sufficient size to accommodate the safety belt buckle, retractor
or inflator.
Obtain a tire and wheel assembly and 4 additional tires (without wheels) of the same size.
With the tire and wheel assembly on the bottom, stack the tires.
Securely tie all of the tires together.

3. Remove the safety belt buckle, retractor or inflator. Refer to the appropriate procedure in Section
501-20A .
When deploying a safety belt buckle pretensioner, install a nut and bolt of sufficient length
and of the same diameter as was used to retain it to the seat.
4. NOTE: If the safety belt anchor, buckle, retractor or inflator does not have a hard-wired pigtail, it will
be necessary to cut the wires and connector(s) from the vehicle wire harness and reconnect to the
safety belt buckle, retractor or inflator.
Cut each of the safety belt anchor, buckle, retractor or inflator wires near the electrical connector that
connects to the vehicle wire harness.
6. Make a jumper harness to deploy the safety belt buckle, retractor or inflator.
wire.
7. NOTE: Typical safety belt retractor pretensioner shown, other safety belt anchor pretensioners,
buckle pretensioners, load-limiting retractors and safety belt inflators similar.
Using the end of the jumper harness that the wires are not connected together, attach each wire of the
jumper harness to each wire of the safety belt anchor, buckle, retractor or inflator. Use tape or other
insulating material to make sure that the leads do not make contact with each other.
8. NOTE: Make sure the safety belt anchor, buckle, retractor or inflator connections are maintained.

Tip the stack of tires on its side and place the safety belt anchor, buckle, retractor or inflator inside the
center tire, making sure that there are 2 tires beneath the tire containing the safety belt anchor, buckle,
retractor or inflator and 2 tires (including the tire and wheel assembly) above the tire containing the
safety belt anchor, buckle, retractor or inflator.
9. Place the tire stack upright, with the wheel on top.
10. Remain at least 9.14 m (30 ft) away from the safety belt anchor, buckle, retractor or inflator.
11. From the end of the jumper harness that is not connected to the safety belt anchor, buckle, retractor or
inflator, disconnect the 2 wires of the jumper harness from each other.
12. Deploy the safety belt anchor pretensioner, buckle pretensioner, retractor pretensioner or inflator by
touching the ends of the 2 wires of the jumper harness to the terminals of a 12-volt battery.
13. To allow for cooling, wait at least 10 minutes before approaching the deployed safety belt anchor
pretensioner, buckle pretensioner, retractor pretensioner or inflator.
14. Dispose of the deployed safety belt anchor, buckle, retractor or inflator in the same manner as any
other part to be scrapped.
Safety Belt Anchor Pretensioners, Safety Belt Buckle Pretensioners, Safety Belt Retractor Pretensioners
and Load Limiting Safety Belt Retractors - In-Vehicle Deployment
pretensioners, load limiters and inflators. Never back probe deployable device electrical connectors.
death.
limiters, etc.) outdoors with all personnel at least 9 meters (30 feet) ay to make sure of personal safety.
Due to the loud report which occurs when an SRS device is deployed, hearing protection is required.
NOTE: A typical safety belt buckle and retractor disposal is shown that is similar for all vehicles.

2. Access the safety belt anchor, buckle or retractor electrical connectors. For additional information,
refer to Section 501-20A .
3. Cut each of the safety belt anchor, buckle or retractor wires, leaving at least 101.6 mm (4 in) to work
with.
5. Make a jumper harness to deploy the safety belt anchor, buckle or retractor.
wire.
6. NOTE: Typical safety belt retractor pretensioner shown, other safety belt anchor pretensioners,
buckle pretensioners and load-limiting retractors are similar.
Using the end of the jumper harness that the wires are not connected together, attach each wire of the
jumper harness to each wire of the safety belt anchor, buckle or retractor. Use tape or other insulating
material to make sure that the leads do not make contact with each other.
7. Remain at least 9.14 m (30 ft) away from the safety belt anchor, buckle or retractor.
8. From the end of the jumper harness that is not connected to the safety belt anchor, buckle or retractor,
disconnect the 2 wires of the jumper harness from each other.
9. Deploy the safety belt anchor pretensioner, buckle pretensioner or retractor pretensioner by touching
the ends of the 2 wires of the jumper harness to the terminals of a 12-volt battery.
10. To allow for cooling, wait at least 10 minutes before approaching the deployed safety belt anchor
pretensioner, buckle pretensioner or retractor pretensioner.
11. Dispose of the deployed safety belt anchor, buckle or retractor in the same manner as any other part to
be scrapped.
Safety Canopy Modules and Side Air Curtain Modules - In-Vehicle Deployment
NOTE: The Safety Canopy module deployment for a scrapped vehicle will occur in its installed position in
the vehicle.
NOTE: A typical Safety Canopy module disposal is shown that is similar for all vehicles.

2. Access the Safety Canopy/side air curtain module electrical connectors. For additional information,
refer to the appropriate procedure in this section.
3. Cut each of the Safety Canopy/side air curtain module wires leaving at least 101.6 mm (4 in) to
work with.
5. NOTE: Typical Safety Canopy/side air curtain module with 2 loops shown, other Safety
Canopy/side air curtain modules wioops are similar.
For Safety Canopy/side air curtain modules with multiple loops, twist together a wire from each
loop then repeat for the remaining wires from each loop.
6. Make a jumper harness to deploy the Safety Canopy/side air curtain module.
wire.
the jumper harness to each wire of the Safety Canopy/side air curtain module or to the
twisted-together wires if multiple loops. Use tape or other insulating material to make sure that the
leads do not make contact with each other.
8. From the end of the jumper harness that is not connected to the Safety Canopy/side air curtain
module, disconnect the 2 wires of the jumper harness from each other.
9. Deploy the Safety Canopy/side air curtain module by touching the ends of the 2 wires of the jumper
harness to the terminals of a 12-volt battery.
10. To allow for cooling, wait at least 10 minutes before apping the deployed Safety Canopy/side air
curtain module.
11. Dispose of the deployed Safety Canopy/side air curtain module in the same manner as any other
part to be scrapped.

Deployable Steering Column - In-Vehicle Deployment
2. NOTE: It may be necessary to lower or remove the deployable steering column from the instrument
panel to access the deployable steering column electrical connector.
Access the deployable steering column electrical connector.
3. NOTE: If the deployable steering column does not ha hard-wired pigtail, it will be necessary to cut
the wires and connector(s) from the vehicle wire harness and reconnect to the deployable steering
column.
Cut each of the deployable steering column wires, leaving at least 101.6 mm (4 in) to work with.
5. Make a jumper harness to deploy the deployable steering column.

wire.
the jumper harness to each wire of the deployable steering column. Use tape or other insulating
material to make sure that the leads do not make contact with each other.
7. Remain at least 9.14 m (30 ft) away from the deployable steering column.
8. From the end of the jumper harness that is not connected to the deployable steering column,
disconnect the 2 wires of the jumper harness from each other.
9. Deploy the deployable steering column by touching the ends of the 2 wires of the jumper harness to
the terminals of a 12-volt battery.
10. To allow for cooling, wait at least 10 minutes before approaching the deployed steering column.
11. Dispose of the deployed steering column in the same manner as any other part to be scrapped.


Rivet Nut Replacement
NOTICE: If the Safety Canopy module has deployed, the tether cord rivet nut must be inspected and
replaced if damaged before installing a new Safety Canopy.
NOTE: The air bag warning lamp illuminates when the Restraints Control Module (RCM) fuse is removed
and the ignition switch is ON. This is normal operation and does not indicate a Supplemental Restraint
System (SRS) fault.
NOTE: A typical rivet nut replacement is shown that is similar for all vehicles.
NOTE: LH drive driver side shown, all others similar.
2. Remove the A-pillar trim panel. For additional information,efer to Section 501-05 .
3. Remove the bolt and bracket for the tether cord from the A-pillar.
4. Position and secure the side air curtain tether cord and bracket assembly out of the way.
5. Using the appropriate service tool, sand the rivet nut shoulder until the shoulder surface is removed.
6. Punch the remaining portion of the rivet nut through the rivet nut hole.
7. NOTE: Use only Ford Motor Company factory-authorized replacement parts for rivet nut repair
procedure.
Obtain the correct square shank rivet nut for the vehicle application from the Ford Catalog
AdvantageTM or equivalent, and insert it into the rivet nut hole.
Rivet Nut Replacement 1032

8. Using a suitable rivet nut installing tool, install the rivet nut. For additional information, refer to the
tool manufacturer's operating instructions.
9. Position the A-pillar tether cord. Install the bolt. See the appropriate component removal and
installation procedure or Specifications for the correct torque specification.
10. NOTE: The tether cord must be positioned correctly in place before installing the A-pillar trim panel.
Install the A-pillar trim panel. For additional information, refer to Section 501-05 .
Rivet Nut Replacement 1033

Air Bag Trim Cover - Passenger
Expedition
Part
2 - Passenger air bag cover window (part of passenger air
bag cover)
3 - Passenger air bag canister hook (part of canister)
4 - Passenger air bag canister (part of 044A74)
5 - Passenger air bag soft pack (part of 044A74)
Navigator
Part
2 -
Air Bag Trim Cover - Passenger 1034

Passenger air bag cover windows (part of passenger air

bag cover)
3 - Passenger air bag canister hooks (part of canister)
4 -
5 - Passenger air bag soft pack (part of 044A74)
Removal
WARNING: Do not use any sharp tools to separate the passenger air bag module trim cover from
the passenger air bag module canister. Sharp tools may damage the passenger air bag module. Failure
to follow this instruction may result in the passenger air bag module deploying incorrectly and
WARNING: Do not unpack or unroll the passenger air bag module soft pack. If the soft pack
becomes unpacked or unrolled, install a new passenger air bag module assembly. Failure follow these
instructions may result in the passenger air bag module deploying incorrectly and increases the risk of
WARNING: Do not manipulate or compromise the passenger air bag module hooks during the
removal or installation procedure. Failure to follow this instruction may result in the passenger air bag
module deploying incorrectly and increases the risk of serious personal injury or death in a crash.
1. Remove the passenger air bag module. For additional information, refer to Passenger Air Bag Module
in this section.
2. Place a mark on top of the passenger air bag module canister for correct installation.
3. Carefully lift the passenger air bag module cover from the bottom of the air bag module canister,
separating the windows from the canister hooks.
4. NOTE: Place an X mark on the old air bag cover to avoid reinstalling.
Remove the passenger air bag cover from the canister, separating the top windows from the canister
hooks.
Navigator 1035
Installation
1. Place the passenger air bag cover on a clean work surface once it is removed from the shipping
package.
2. WARNING: Carefully inspect the passenger air bag trim cover, canister and soft pack
before assembly. If any foreign objects are found, remove them before attaching the passenger
air bag trim cover to the canister. If the canister or soft pack is damaged, install a new
passenger air bag module assembly. Failure to follow this instruction may result in the
passenger air bag module deploying incorrectly, which increases the risk of serious personal
Match the number of cover windows to the number of canister hooks before attaching the passenger
air bag cover to the canister.
3. Match the top of the passenger air bag cover with the canister mark from the removal procedure.
4. Position the canister onto the passenger air bag cover and engage the bottom hooks into the air bag
cover windows.
5. Push the top of the passenger air bag cover to engage the top canister hooks.
6. Inspect the passenger air bag cover windows-to-canister hooks to verify that every window has a hook
installed and the sides are not tucked or folded against the air bag canister.
7. Install the passenger air bag module. For additional information, refer to Passenger Air Bag Module
in this section.
8. NOTE: The video utilizes an F-Super Duty passenger air bag module assembly. It also applies to
vehicles with similar passenger air bag module designs.
Click here to view a video version of this procedure.
Navigator 1036
Navigator 1037
Clockspring

1 3F888 Multifunction switch carrier
2 14A664 Clockspring
3 W506943 Clockspring screws
4 - Clockspring electrical connector (part of 14401)
Removal
Depowering and Repowering in the General Procedures portion of this section.
3. Remove the driver air bag module. For additional information, refer to Driver Air Bag Module in this
section.
4. NOTICE: To prevent damage to the clockspring, make sure the road wheels are in the
straight-ahead position.
Remove the steering wheel. For additional information, refer to Section 211-04 .
5. Disconnect the clockspring electrical connector.
6. Remove the 2 screws and clockspring.
Installation
1. NOTICE: If installing a new clockspring, do not remove the clockspring anti-rotation key until
the steering wheel is installed. If the anti-rotation key has been removed before installing the
Clockspring 1038
steering wheel, the clockspring must be centered. Failure to follow this instruction may result in
component damage and/or system failure.
Install the clockspring and 2 screws.
2. Connect the clockspring electrical connector.
3. WARNING: If the clockspring is not correctly centralized, it may fail prematurely. If in

doubt, repeat the centralizing procedure. Failure to follow these instructions may increase the
risk of serious personal injury or death in a crash.
NOTICE: To prevent component damage and/or system failure, when reusing a clockspring it
must be centered.
NOTICE: Do not over-rotate the clockspring inner rotor. The internal ribbon wire is connected
to the clockspring rotor. The internal ribbon wire acts as a stop and can be broken from its
internal connection. Failure to follow this instruction may result in component damage and/or
system failure.
If a new clockspring was installed and the anti-rotaion key has not been removed, proceed to Step 5.
If a new clockspring was installed and the anti-rotation key has been removed before the steering
wheel is installed or the same clockspring is being installed, rotate the clockspring inner rotor
counterclockwise and carefully feel for the ribbon wire to run out of length with slight resistance.
Stop rotating the clockspring inner rotor at this point.
4. Starting with the clockspring rotor wiring and connector in the 12 o'clock position, rotate the
clockspring rotor clockwise through two and one-quarter to two and one-half revolutions until the
clockspring rotor wiring and connector are in the 12 o'clock position. The clock spring is now
centered.
Verify that the clockspring is correctly centralized by observing that the clockspring rotor, wiring and
connector are in the 12 o'clock position.
5. NOTICE: To prevent damage to the clockspring, make sure the road wheels are in the
NOTE: The clockspring inner rotor, wiring and connector must be in the 12 o'clock position to install
the steering wheel.
Install the steering wheel. For additional information, refer to Section 211-04 .
6. If a new clockspring was installed, remove the anti-rotation key.
Clockspring 1039
7. Install the driver air bag module. For additional information, refer to Driver Air Bag Module in this
section.
Clockspring 1040
Part
1 - Driver air bag module electrical connectors (part of
14A664)
2 - Horn switch electrical connector (part of 3600)
3 3530 Steering column upper shroud
4 3K512 Steering column lower shroud
5 W710485 Steering column lower shroud screws (3 required)
6 - Driver air bag module wire clip (part of 043B13) (3
required)
7 043B13 Driver air bag module
8 - Driver air bag module locator pin (part of 043B13) (2
required)
modules. Failure to follow this instruction may result in the accidental deployment of thes, which
increases the risk of serious personal injury or death.
Driver Air Bag Module 1041

1. Make sure the road wheels are in the straight-ahead position.
3. NOTICE: Turn the steering wheel such that the top is at 90 degrees (at the 9 o'clock position) to
the left from the straight-ahead position to access the driver air bag module wire clips and to
prevent damage to the steering column multifunction switch. Failure to follow this instruction
may result in component damage.
Turn the steering wheel so the top of the wheel is 90 degrees to the left (at the 9 o'clock position).
5. Remove the lower steering column opening cover.

Pull out and release the top retainers.
Remove the lower steering column opening cover.
If equipped, disconnect the adjustable pedals switch connector.
6. If equipped, remove the screw and steering column manual tilt lever.
7. Remove the 3 steering column lower shroud screws.
8. Release the clips and remove the steering column upper shroud.

If equipped, disconnect the power tilt steering column switch located on the lower shroud.
10. NOTICE: Make sure each of the 3 driver air bag module wire clips are disengaged from each of
the 3 steering wheel hooks before removing the driver air bag module from the steering wheel.
Failure to follow this instruction may result in component damage and/or system failure.
NOTE: Use a mirror to view the rear of the steering wheel to locate where the 3 driver air bag
module wire clips attach to the steering wheel hooks.
Using a screwdriver or a suitable tool, release each of the 3 driver air bag module wire clips from the
steering wheel hooks.
Access the 3 driver air bag module wire clips through the back of the steering wheel cover
and push the wire clips toward the center of the steering wheel to release.
11. Disconnect the 2 driver air bag module electrical connectors, horn switch connector and remove the
driver air bag module.
12. Turn the steering wheel so the top of the wheel is back in the straight ahead 12 o'clock position.
Installation
1. Connect the horn switch connector and 2 driver air bag module connectors.

2. Position the driver air bag module to the steering wheel lining up the locator pins.
3. NOTE: For correct installation, make sure all 3 driver air bag module wire clips are fully engaged
and seated correctly to the steering wheel.
Firmly press the driver air bag module to the steering wheel, seating the 3 driver air bag module wire
clips to the steering wheel hooks.
Check the driver air bag module trim cover to the steering wheel for an even gap clearance
and correct movement.
4. Install the steering column lower shroud.

If equipped, connect the power tilt steering column switch located on the lower shroud.
5. Install the steering column upper shroud.
6. Install the 3 steering column lower shroud screws.
7. If equipped, install the steering column manual tilt lever and screw.
8. If equipped, connect the adjustable pedals switch connector.
9. Install the lower steering column opening cover and 3 screws.


Front Impact Severity Sensor
Part
1 - Front impact severity sensor electrical connector (part
of 14290)
2 W711619 Front impact severity sensor bolt
3 14B345 Front impact severity sensor
in a crash.
NOTE: The front impact severity sensor is located on the bottom of the lower radiator support.
1. Depower the SRS . For additional information, refer to Supplemental Reraint System (SRS)
2. Disconnect the front impact severity sensor electrical connector.
3. WARNING: Always tighten the fasteners of the restraints control module (RCM) and
impact sensor (if equipped) to the specified torque. Failure to do so may result in incorrect
restraint system operation, which increases the risk of personal injury or death in a crash.
NOTE: Make sure the radiator support and front impact severity sensor mating surfaces are clean and
free of foreign material.
Front Impact Severity Sensor 1046

Remove the bolt and the front impact severity sensor.
Front Impact Severity Sensor 1047

Passenger Air Bag Module
Expedition

3 W707628 Passenger air bag cover screws
4 - Passenger air bag module electrical connector
(part of 14401)
5 W709027 Passenger air bag module bolts
Navigator
Passenger Air Bag Module 1048


3 - Passenger air bag module electrical connector
(part of 14401)
4 - Glove compartment door dampener (if
equipped)
5 W709027 Passenger air bag module bolts
deployment door/trim cover/tear seam face down. Failure to follow ructions may result in serious
personal injury in the event of an accidental deployment.
NOTICE: Do not install a new passenger air bag module assembly due to a damaged or discolored
passenger air bag cover. The passenger air bag cover can be serviced separately from the passenger air
bag module assembly. For additional information, refer to Air Bag Trim Cover - Passenger in this
section.
All vehicles
Navigator 1049
2. Lower the glove compartment door.
3. Disconnect the passenger air bag module electrical connector.
Expedition vehicles
4. Remove the 4 passenger air bag trim cover screws.
All vehicles
5. Remove the 4 passenger air bag module bolts.

6. Push out on the bottom of the passenger air bag cover to release the bottom trim cover clips from the
instrument panel and remove the passenger air bag module.
7. NOTE: For correct installation, make sure all trim cover clips are fully seated into the instrument
panel.
Navigator 1050
NOTE: Seats removed for clarity.
Part
1 W710898 Restraints Control Module (RCM) bolts (3 required)
2 - Small RCM electrical connector (part of 14A005)
3 - Large RCM electrical connector (part of 14A005)
4 14B321 RCM
5 W623482 RCM cover pushnut retainers (vehicles with bucket seats
and no center console only)
6 14A099 RCM cover (vehicles with bucket seats and no center
console only)
Removal
in a crash.
WARNING: Do not handle, move or change the original horizontal mounting position of the restraints
control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to follow this
instruction may result in the accidental deployment of the Safety Canopy and cause serious personal injury
or death.
NOTICE: When installing a new Restraints Control Module (RCM), it is necessary to carry out
Restraints Control Module (RCM) 1051

Programmable Module Installation (PMI). For additional information, refer to Section 418-01 . When
installing a new RCM , always make sure the correct RCM is being installed. If an incorrect RCM is
installed, erroneous Diagnostic Trouble Codes (DTCs) will result.
NOTE: The Supplemental Restraint System (SRS) must be fully operational ad free of faults before releasing
the vehicle to the customer.
All vehicles
NOTE: Carrying out Programmable Module Installation (PMI) will not enable the 911 assist option that is
disabled. The RCM and Accessory Protocol Interface Module (APIM) must be configured correctly to fully
support 911 assist functionality.
1. When installing a new RCM , carry out the appropriate steps necessary for the PMI procedure. For
Vehicles with center console
3. Remove the center console. For additional information, refer to Section 501-12 .
Vehicles with bucket seats without center console
4. Position the carpet aside and remove the 3 RCM pushnut retainers and the RCM cover.
All vehicles
5. Disconnect the small RCM electrical connector.

1. Push down to release the retaining tab.
2. While releasing the retaining tab, pull out and disconnect the small RCM electrical connector.
6. Disconnect the large RCM electrical connector.

1. Pinch the thumb tab and pivot the connector position assurance lever away from the RCM ,
disengaging the lever.
2. Pull out and disconnect the large RCM electrical connector.

7. Remove the 3 bolts and RCM .
Installation
All vehicles
Install the RCM and 3 bolts.
2. Make sure the connector position assurance lever is in the full release position before attempting to
connect the connector.
3. NOTICE: Putting the large Restraints Control Module (RCM) electrical connector into the
RCM on an angle can cause bad electrical connections and damage components.
Position the large electrical connector into the RCM .
NOTICE: Do not push on the connector so that the lever pivots and seats itself. Light
pressure is needed to get the connector into position on the Restraints Control Module
(RCM) before using the lever to fully seat the connector.
With the large RCM electrical connector uniformly aligned to the RCM , lightly push in until
a subtle audible click is heard and slight resistance is felt.
4. Connect the RCM electrical connector.

Pivot the connector position assurance lever toward the RCM , drawing the connector in to
the RCM .

Make sure the thumb tab is engaged to the retainer on the RCM and locked in place.
5. Connect the small RCM electrical connector.
Vehicles with bucket seats without center console
6. Install the 3 pushnut retainers and RCM cover.
Vehicles with center console
7. Install the center console. For additional information, refer to Section 501-12 .
All vehicles
9. If a new RCM was installed, carry out the appropriate steps in the Programmable Module Installation
(PMI) procedure. For additional information, refer to Section 418-01 .
10. Prove out the SRS as follows:

Turn the ignition switch from ON to OFF. Wait 10 seconds, then turn the ignition switch back to ON
and visually monitor the air bag warning indicator with the air bag modules installed. The air bag
warning indicator will light continuously for approximately 6 seconds and then turn OFF. If an air bag
SRS fault is present, the air bag warning indicator will:
- fail to light.
- remain lit continuously.
- flash.
The air bag warning indicator might not light until approximately 30 seconds after the ignition switch
has been turned from the OFF to the ON position. This is the time required for the RCM to complete
the testing of the SRS . If the air bag warning indicator is inoperative and a SRS fault exists, a chime
will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag warning indicator and any SRS

fault discovered must be diagnosed and repaired.

Clear all continuous memory DTCs from the RCM .

Safety Canopy Module
NOTE: Expedition shown, other models similar.

1 042D94 Safety Canopy module
RH/042D95 LH
2 - Front tether cord bracket bolt (part of 042D94/95)
3 - Front tether pin-type retainers (part of 042D94/95)
4 - Safety Canopy module electrical connector (part
of 14A005)
5 W706681 Safety Canopy module C-pillar bolt
6 W706681 Safety Canopy module rear bolts
7 W706681 Safety Canopy module front bolts
8 W706681 Safety Canopy module B-pillar bracket bolt
9 - Safety Canopy module rear tether cord routing
clip pin-type retainer (part of 042D94/95)
10 - Safety Canopy module rear tether cord anchor
bracket (part of 042D94/95)
11 W706681 Safety Canopy module rear tether anchor bracket
bolt
Removal
and new A-, B-, C- and D-pillar upper trim panels and attaching hardware must be installed. Remove
any other damaged components and hardware and install new components and hardware as needed.
Failure to follow these instructions may result in the Safety Canopy or side air curtain module
Safety Canopy Module 1056

deploying incorrectly and increases the risk of serious personal injury or death in a crash.
WARNING: Do not obstruct or place objects in the deployment path of the Safety Canopy or side
air curtain module. Failure to follow this instruction may result in the Safety Canopy or side air
curtain module deploying incorrectly and increases the risk of serious personal injury or death in a
crash.
NOTE: The Supplemental Restraint System (SRS) must be fully operational andee of faults before releasing
the vehicle to the customer.
All vehicles
Vehicles with a moonroof
3. Disconnect the moon roof rear drain hose and release the drain hose retainer from the coat hook
bracket.
All vehicles
4. Disconnect the Safety Canopy module electrical connector.
5. NOTE: Note the locator tab on the front tether anchor bracket to the A-pillar sheet metal for
installation.
Remove the front tether bolt and bracket from the A-pilar.
6. Remove the 2 front tether cord pin-type retainers from the A-pillar sheet metal.
7. Remove the 2 Safety Canopy module front bolts and the one B-pillar bracket bolt.

Expedition/Navigator vehicles
8. Detach the Safety Canopy module rear tether cord routing clip pin-type retainer from the sheet
metal.
9. NOTE: Note the locator tab on the rear tether cord anchor bracket to the D-pillar sheet metal for
installation.
Remove the bolt and the Safety Canopy module rear tether cord anchor bracket from the D-pillar.
Expedition EL/Navigator L vehicles
10. Detach the 3 Safety Canopy module rear tether cord routing clip pin-type retainers from the sheet
metal.
11. NOTE: Note the locator tab on the rear tether cord anchor bracket to the D-pillar sheet metal for
installation.
Remove the bolt and the Safety Canopy module rear tether anchor bracket from the D-pillar.
All vehicles
12. Remove the C-pillar Safety Canopy module bolt.
13. Remove the 2 Safety Canopy module rear bolts.
Gently lift the Safety Canopy module up and inward at the B-pillar to release the bracket hook from the
sheet metal.
15. Move the Safety Canopy module forward to release the rear bracket hook from the sheet metal and
remove the Safety Canopy module.

Installation
All vehicles
WARNING: Never put any type of fastener or tie strap around any part of a Safety Canopy
module, side air curtain module or interior trim panel. This will prevent the Safety Canopy or side air
curtain module from deploying correctly. Failure to follow this instruction may increase the risk of
WA: When installing a new headliner on a vehicle equipped with Safety Canopy or side air curtain
modules, make sure the headliner has the word AIRBAG on the headliner where it meets each B-pillar
trim panel. Otherwise, you have the wrong headliner. Failure to follow this instruction may result in the
Safety Canopy or side air curtain module not deploying or deploying incorrectly, increasing the risk
of personal injury or death in a crash.
WARNING: Before installing a Safety Canopy or side air curtain module, inspect the roofline for
any damage. If necessary, the sheet metal must be reworked to its original condition and structural
integrity. Install new fasteners if damaged and remove foreign material. Failure to follow these
instructions may result in the Safety Canopy or side air curtain deploying incorrectly, which increases
the risk of serious personal injury or death in a crash.
WARNING: Inspect a Safety Canopy or side air curtain module before installation. If the module
is damaged, the cover has separated or the Safety Canopy or side air curtain material has been
exposed, install a new module. Do not attempt to repair the module. Failure to follow these instructions
may result in the Safety Canopy or side air curtain deploying incorrectly, which increases the risk of
1. P the Safety Canopy module by moving it rearward, installing the rear bracket hook in the sheet
metal.
2. Install the Safety Canopy module B-pillar bracket hook in the sheet metal.

3. Install the Safety Canopy module B-pillar bracket bolt.
4. Install the 2 Safety Canopy module rear bolts.

5. Install the C-pillar Safety Canopy module bolt.

Expedition EL/Navigator L vehicles
6. Install the Safety Canopy module rear tether anchor bracket and bolt to the D-pillar.
7. Attach the 3 Safety Canopy module rear tether routing clip pin-type retainers theet metal.
Expedition/Navigator vehicles
8. Install the Safety Canopy module rear tether anchor bracket and bolt to the D-pillar.
9. Attach the Safety Canopy module rear tether routing clip pin-type retainer to the sheet metal.
All vehicles
10. Install the 2 Safety Canopy module front bolts.

11. Install the 2 front tether pin-type retainers in the A-pillar sheet metal.
12. Install the front tether bracket and bolt in the A-pillar.
13. Connect the Safety Canopy module electrical connector.
Vehicles with a moonroof
14. Connect the moonroof rear drain hose and attach the drain hose retainer to the coat hook bracket.

All vehicles

Seat Position Sensor
NOTE: Power seat shown, manual similar.

1 - Seat position sensor electrical connector (part of
14A699)
2 - Seat position sensor and bracket bolt (part of 14B416)
3 14B416 Seat position sensor and bracket
1. Move the driver seat to the full forward and highest position.
2. Change to Ignition Off. Wait 1 minute.
3. Remove the seat position sensor and bracket bolt.
4. Unhook the seat position sensor and bracket from the seat track cross brace.
5. Disconnect the electrical connector and remove the seat position sensor and bracket.
Seat Position Sensor 1062

Seat Position Sensor 1063

Side Air Bag Module

1 - Side air bag module electrical connector (part of
14K155)
2 611D10 Side air bag module
3 - Side air bag module locator pin (part of 611D10)
4 N620480 Side air bag module nuts
5 - Seat backrest trim cover and foam pad
WARNING: If the seat side air bag cover has been damaged or separated from its mounting, or if
the air bag material has been exposed, install a new seat side air bag module. Never try to repair the
seat side air bag module. Failure to follow these instructions may result in the seat side air bag
deploying incorrectly, which increases the risk of serious personal injury or death in a crash.
WARNING: Front seat backrest trim covers installed on seats equipped with seat side air bags
cannot be repaired. A new trim cover must be installed. Cleaning is permissible. Failure to follow these
instructions may result in the seat side air bag module deploying incorrectly and increase the risk of
NOTE: If a side air bag deployment took place, a new seat back pad, trim cover, side air bag module and nuts
must be installed. The seat back frame should be replaced if necessary. For additional information, refer to
front seat backrest disassembly and assembly procedure in Section 501-10 .
Side Air Bag Module 1064

1. Move the seat to the full forward and highest position.
3. Release the seat backrest cover lower rear J-clip and unzip the 2 side zippers.
4. NOTE: Note the position of the side air bag module locator pin to the seat backrest frame for
installation.
Remove the 2 side air bag module nuts.
5. Position the backrest foam aside and remove the side air bag module from the backrest frame. Then
slide the side air bag module out of the seat backrest cover deployment chute.
For correct installation, position the locator pin and mounting studs through the holes in the
deployment chute and backrest frame.

WARNING: If the seat side air bag cover has been damaged or separated from its mounting,
or if the air bag material has been exposed, install a new seat side air bag module. Never try to
repair the seat side air bag module. Failure to follow these instructions may result in the seat
side air bag deploying incorrectly, which increases the risk of serious personal injury or death
in a crash.

Side Impact Sensor - C-Pillar
NOTE: Expedition/Navigator shown, Expedition EL/Navigator L similar.
NOTE: RH side shown, LH side similar.
Part
1 13228 Rear door scuff plate
2 253A10 Rear door weatherstrip
3 14B345 Side impact sensor
4 W711619 Side impact sensor bolt
5 - Side impact sensor electrical connector (part of
14A005)
6 31012 Quarter trim panel
7 - Second row safety belt anchor (part of 611B68
RH/611B69 LH)
8 - Second row safety belt anchor bolt (part of 611B68
RH/611B69 LH)
impact sensor (if equipped) mounting areas for deformation. If damaged, restore the mounting
areasiginal production configuration. A new RCM and sensors must be installed whether or not the air
in a crash.
NOTE: The air bag warning indicator illuminates when the correct Supplemental Restraint System (SRS)
fuse is removed and the ignition is ON.
2. Remove the rear door scuff plate.
Side Impact Sensor - C-Pillar 1067

3. Detach the rear door weatherstrip.
4. Remove the bolt and second row safety belt anchor.

5. Position aside the quarter trim panel.

Pull out on the quarter trim panel at the C-pillar and release the retaining clips to gain access
to the C-pillar side impact sensor.
NOTE: Make sure the C-pillar and side impact sensor mating surfaces are clean and free of foreign
material.
Remove the bolt, disconnect the electrical connector and remove the side impact sensor.
7. NOTE: Before installation, make sure the safety belt webbing is not twisted and the safety belts and
buckles are accessible to the occupants.
Side Impact Sensor - C-Pillar 1068

Side Impact Sensor - Front Door
NOTE: RH door shown, LH similar.

1 14B345 Side impact sensor (pressure sensor)
2 W506966 Side impact sensor bolts
3 - Side impact sensor electrical connector (part
of 14630)
in a crash.
releasing the vehicle toustomer.
3. Separate the weathershield from the door enough to access the side impact sensor.
4. Slide the locking wedge back and disconnect the side impact sensor electrical connector.
5. Remove the 2 bolts and side impact sensor.

Side Impact Sensor - Front Door 1069

6. NOTICE: To prevent stripping the insert nuts, tighten the side impact sensor bolts only enough
to retain the side impact sensor correctly.
Inspect the insert nut for damage. If the insert nut is damaged, install a new insert.

SECTION 501-35: Body Repairs 2011 Expedition, Navigator Workshop Manual

Material

Capacity
Clear Silicone Rubber ESB-M4G92-A -
TA-32
Flexible Foam Repair - -
Fusor 121, or equivalent; obtain
locally
Metal Bonding Adhesive - -
TA-1
Motorcraft Acid Neutralizer - -
ZC-1-A
Motorcraft Alkaline Neutralizer - -
ZC-2-A
3MTM Perfect-ItTM Show Car - -
Liquid Wax
39026
Motorcraft Detail Wash - -
ZC-3-A
Motorcraft Metal Surface Prep - -
ZC-31-A
Premium Undercoating - -
ValuGardTM VG101, VG101A
(aerosol)
Rust Inhibitor - -
(aerosol)
Plastic Bonding Adhesive - -
TA-9
Seam Sealer - -
TA-2
Structural Foam (Medium) - -
Fusor 1908; obtain locally
Trim and Weatherstrip Adhesive - -
Permatex 81850 or equivalent
Item Specification
Wax and Grease Remover -

Compuspot
700F
Welder
190-50080
I4 Inverter
Spot
Welder
254-00014
Inverter
Welder
with MIG
Welder
254-00015
Cowl side panel-to-A-pillar bolt 12 106
General Specifications -Welding Specifications
Item Specification
Plug Weld Hole 8 mm (0.31 in)
Weld Wire ER70S-3 or equivalent 0.9-1.1 mm
(0.035-0.045 in)
Weld Nugget Chart
Test Thickness of Metal (in millimeters) Nugget Size

0.7 + 0.7 4.3 mm (0.16 in)
0.7 + 0.7 + 0.7 4.3 mm (0.16 in)
0.9 + 0.9 4.7 mm (0.18 in)
0.9 + 0.9 + 0.9 4.7 mm (0.18 in)
1.0 + 1.0 5.2 mm (0.2 in)
1.0 + 1.0 + 1.0 5.2 mm (0.2 in)
2.0 + 2.0 7.1 mm (0.27 in)
2.0 + 2.0 + 2.0 7.1 mm (0.27 in)
3.0 + 3.0 8.7 mm (0.34 in)
3.0 + 3.0 + 3.0 8.7 mm (0.34 in)
3.0 + 0.7 4.3 mm (0.16 in)

0.7 + 3.0 + 1.0 5.2 mm (0.2 in)

2.0 + 2.0 + 0.7 4.3 mm (0.16 in)
0.9 + 0.9 + 2.0 4.7 mm (0.18 in)
2.0 + 0.9 + 1.0 5.2 mm (0.2 in)
1.0 + 3.0 + 1.0 5.2 mm (0.2 in)
3.0 + 1.0 + 2.0 7.1 mm (0.27 in)
0.9 + 0.7 + 0.9 4.3 mm (0.16 in)
Descriptions of Ford Steel Families
Typical
Grade Alloy Content Heat Treatment Applications Comments
Mild Steel, Bake Low Fully annealed/dead Body panels -
Hardened, Solid soft (closures, floor pan,
Solution dash panel)
Strengthened
High-Strength Low Low Fully annealed/dead Rails, structural Strengthened with
Alloy (HSLA) soft members fine particles and
small grain size
Dual Phase Medium Fully Rails, structural 15-50% of structure
(Manganese Silicon, annealed/partially members is hard martensite
Molybdenum hardened
Chromium)
Ultra High Strength Low Fully hardened Rocker 100% of structure is
Steel (UHSS) reinforcements, door hard martensite
(Martensitic, Boron) beams, bumper
beams
Transformation High (Manganese, Fully annealed/ To be determined Complex
Induced Plasticity Phosphorous, partially hardened microstructure for
Steel Silicon, Aluminum) high strength and
ductility
Ford Recommended Steel Repairability Matrix
Welding Method
Squeeze-
Metal Type Resist-
Trade Inert ance Spot Use of Temp- Max-
Descrip- Gas Welding MIG Cold Heat for erature imum
Gre tions (MIG) (STRW) Braze Repairs Repair Range Heat
Mild Steel Mild Yes Yes NA Yes a Yes Up to 90 sec.
650C x2
(1,200F)
Laminate Steel Quiet Steel No Yes No Yes a NA NA NA

Bake Hardened BH 180, Yes Yes Yes b Yes a Yes Up to 90 sec.

BH210, BH 650C x2
250, BH (10F)
280
Solid Solution - Yes Yes Yes b Yes a Yes Up to 650 90 sec.
Strength- ened C (1,200F) x 2
High- Strength HSLA 250, Yes Yes Yes b Yes a Yes Up to 90 sec.
Low Alloy HSLA 350, 650C x2
(HSLA) HSLA 550 (1,200F)
Dual Phase = 600 DP 500, DP Yes Yes Yes b Yes a No NA NA
MPa Ultimate 600
Tensile Strength
Dual Phase = 600 DP 700, DP Yes d Yes Yes b No No NA NA
MPa Ultimate 780, DP 900
Tensile Strength
(particular to 780
and 980 grades) c
Ultra High Boron Yes a Yes Yes b No No NA NA
Strength Steel
(UHSS) (Martens-
itic, Boron) e
Transform- ation TRIP 590, NA NA NA NA NA NA NA
Induced Plasticity TRIP 780,
(TRIP) Steel TRIP 980
a Cold repairs can be performed if damage excludes kinks. May section only if approved procedure in
workshop manual.
b MIG braze allowed for non-structural applications only.
c Dual phase steels DP 700, DP 780 and DP 980 must be replaced at factory joints, no sectioning unless
approved procedure in workshop manual.

d For DP 980, use MIG plug welding only, no stitch welding.
e Boron components must be replaced at factory joints, no sectioning allowed.


Adhesives
Material
Item Specification
Clear Silicone Rubber TA-32 ESB-M4G92-A
Metal Bonding Adhesive TA-1 -
Motorcraft Metal Surface Prep ZC-31-A -
Plastic Bonding Adhesive TA-9 -
Trim and Weatherstrip Adhesive TA-14-A -
NOTE: Corrosion protection needs to be restored whenever it is necessary to grind through painted surfaces
or E-coat, or when bare metal repairs are made. Refer to Restoring Corrosion Protection Following Repair in
this section.
Adhesives are used in a variety of applications. Typical uses for adhesives include roof panels, door skins and
quarter panels. Trim applications include body side mouldings, emblems, stationary glass and
weatherstripping. Combination sealer/adhesives are also used. Surface preparation is critical to a high quality
repair. Following the label instructions for the product is essential.
Work in a well-ventilated area and protect adjacent surfaces when working wiives. The use of eye protection
and protective clothing is also recommended when working with adhesives. Carry out a trial fit, mark and
align the surfaces before bonding the materials together.
Seam sealers and corrosion protection may be necessary once the adhesive(s) has cured, depending on the
application. The following is a list of adhesives recommended for certain types of applications:
Metal Bonding Adhesive - For bonding cold-rolled steel, galvanized steel, aluminum and correctly
prepared E-coat. It is used for door skin and roof panel replacement and OEM structural adhesive
replacement.
Plastic Bonding Adhesive - For bonding a variety of plastics to plastics and plastics to primed, painted
or E-coated metals. Also for general purpose bonding of trim components.
Trim and Weatherstrip Adhesive - For use on body side moulding, emblems, trim, bumper impact
strips and carpeting.
Clear Silicone Rubber - Used for sealing water leaks, noise concerns, remounting trim and repairing
torn weatherstripping.
NOTE: The following illustrations identify structural adhesive locations.
Quarter Panel Corner
Adhesives 1075
Underbody - Rear Sill
&n/body>
Quarter Panel Corner 1076


Body
WARNING: Collision damage repair must conform to the instructions contained in this workshop
manual. Replacement components must be new, genuine Ford Motor Company parts. Recycled,
salvaged, aftermarket or reconditioned parts (including body parts, wheels or safety restraint
components) are not authorized by Ford.
Departure from the instructions provided in this manual, including alternate repair methods or the use
of substitute components, risks compromising crash safety. Failure to follow these instructions may
adversely affect structural integrity and crash safety performance, which could result in serious
personal injury to vehicle occupants in a crash.
The body consists of the following:
Body-on full-frame design

High-Strength Low Alloy (HSLA), high-strength and mild steels
Unique front structure constructed of high-strength hydroformed steel tubes
Upper rail of radiator support constructed of magnesium
Lower rail of radiator support constructed of hydroformed high-strength steel
Expedition hood constructed of aluminum
Navigator hood constructed of Sheet-Molded Composite (SMC) plastic
Bolt-on high-strength front bumper beam
Expedition and Navigator have unique front fascia, grille and headlamps
Bolted, removable front fenders, hinged doors, liftgate and hood
Steel doors
Steel fenders
Steel quarter panels
Expedition and Navigator liftgate constructed of aluminum
Welded-on high-strength rear bumper beam
Standard 3023 mm (119 in) and optional 3327 mm (131 in) wheelbase
Structural adhesive used in rear sill and quarter panel D-pillar inner to outer panel
Structural foam with nylon insert used in D-pillar
Sound deadener material used on floor pans
For dimensional information, refer to the following illustrations:
Body Margins
NOTE: Dimensions apply to right and left side.
NOTE: The hood to fender underflush specification is 1.2 mm (0.047 in) 2.0 mm (0.078 in). The hood
should not be adjusted if it is within the above specification as this is design intent.
Underbody - Rear Sill 1077

Item Description Margin Specification Flushness Specification

1 Grille to fascia 1.6 mm (0.062 in) 0.5 mm (0.01 in) -
(Expedition)
2.0 mm (0.078 in) 0.5 mm (0.019 in)

(Navigator)
2 Hood to grille 6.5 mm (0.25 in) 2.5 mm (0.09 in) 2.2 mm (0.086 in) 2.0 mm (0.078
in)
3 Headlamp to grille 4.0 mm (0.15 in) 2.5 mm (0.09 in) -
4 Hood to headlamp 6.5 mm (0.25 in) 2.5 mm (0.09 in) -
5 Headlamp to 4.0 mm (0.15 in) 2.0 mm (0.07 in) -
fascia
6 Fender to 4.0 mm (0.15 in) 2.0 mm (0.07 in) 1.3 mm (0.051 in) 2.5 mm (0.098
headlamp in)
7 Hood to fender 4.5 mm (0.17 in) 2.0 mm (0.07 in) -1.2 mm (-0.047 in) 2.0 mm
(0.078 in)
Body Margins
Item Description
8 Fascia to fender 0.0 mm (in) 1.5 mm (0.05 in) -1.5 mm (-0.059 in) 1.5 mm
(0.059 in)
9 Front door to fender 0.0 mm ( in) 2.0 mm (0.078 in)
Body Margins 1078

4.5 mm (0.17 in) 2.0 mm (0.07

in)
10 Front door to rear door 4.5 mm (0.17 in) 2.0 mm (0.07 0.0 mm ( in) 2.0 mm (0.078 in)
in)
11 Front door to rear door 4.5 mm (0.17 in) 2.0 mm (0.07 0.0 mm ( in) 2.0 mm (0.078 in)
(upper) in)
12 Door to roof 5.0 mm (0.196 in) 0.0 mm ( in)
13 Glass to quarter panel 5.0 mm (0.19 in) 2.5 mm (0.09 2.0 mm (0.078 in) to 8 mm
in) (0.314 in) (Exped)
4 mm (0.157 in) to 10 mm (0.393

in) (Navigator)
14 Rear door to quarter panel 4.5 mm (0.17 in) 2.0 mm (0.078 0.0 mm ( in) 2.0 mm (0.078 in)
in)
15 Tail lamp to rear fascia
16 Tail lamp to quarter panel 2.0 mm (0.07 in) 1.9 mm (0.074 3.5 mm (0.137 in) 2.4 mm
in) (0.094 in) (Expedition)
1.5 mm (0.059 in) 1.5 mm

(0.059 in) (Navigator)
17 Liftgate to quarter panel 5.0 mm (0.19 in) 2.5 mm (0.09 -1.5 mm (-0.059 in) 2.0 mm
in) (0.078 in)
18 Glass to D-pillar outer panel 5.5 mm (0.21 in) 2.5 mm (0.09 -4.0 mm (-0.157 in) 2.0 mm
in) (0.078 in)
19 Liftgate to roof 10.0 mm (0.39 in) 2.5 mm (0.09 -2.0 mm (-0.078 in) 2.0 mm
in) (0.078 in)
20 Liftgate to fascia 3.0 mm (0.11 in) 1.0 mm (0.03 -
in)
21 Liftgate to quarter panel 5.0 mm (0.19 in) 2.5 mm (0.09 -1.5 mm (-0.059 in) 2.0 mm
in) (0.078 in)
Underhood Dimensions
NOTE: Measurements are obtained on center, unless otherwise indicated.
Body Margins 1079

Body Side Dimensions
NOTE: Expedition 3327 mm (131 in) extended wheelbase shown, front door opening is common to all
models.
Rear Door Opening - 3023 mm (119 in) Wheelbase
Rear Door Opening - 3023 mm (119 in) Wheelbase 1080

Body Rear Opening Dimensions
NOTE: Dimensions common to all models.
Underbody Dimensions
Frame Datum Height
NOTE: Datum measurements indicated from front (No. 1) to the rear (No. 6). The gauge for the No. 3 datum
measurement is located 28 mm (1.1 in) rearward from the transmission No. 3 crossmember flange. Inset views
indicated from left side.
Frame Datum Height 1081

Frame Dimensions - 3023 mm (119 in) Wheelbase
NOTE: A structural frame rail sectioning kit is available for the front frame rail section. It is mandatory to
maintain factory frame dimensions when carrying out any repair procedure to the frame. Refer to Frame
Members in this section.
Frame Dimensions - 3327 mm (131 in) Wheelbase
NOTE: A structural frame rail sectioning kit is available for the front frame rail section. It is mtory to
maintain factory frame dimensions when carrying out any repair procedure to the frame. Refer to Frame
Members in this section.
Frame Dimensions - 3023 mm (119 in) Wheelbase 1082

Frame Dimensions - 3327 mm (131 in) Wheelbase 1083


Plastic Components
Exterior Plastic Components - Painted
NOTE: The following illustration(s) are not all-inclusive of trim levels available. The actual trim level of the
vehicle will determine the viability of carrying out a plastic repair.

1 40010 Liftgate (Navigator) - Sheet-Molded Composite
(SMC)
2 17K835 Bumper cover (rear) - Thermoplastic Olefin
(TPO)
3 25557 LH/ 25556 Wheel arch molding (rear) - TPO
RH
4 20879 LH/ 20878 Door molding (rear) - TPO
RH
5 20879 LH/ 20878 Door molding (front) - TPO
RH
6 16612 Hood (Navigator) - SMC
7 16039 LH/ 16038 Wheel arch molding (front) - TPO
RH
8 17D597 Bumper cover (front) - TPO
Liftgate Applique - Navigator
Plastic Components 1084

Part
1 404C42 Liftgate applique - Polycarbonate (PC) + Acrylonitrile
Butadiene Styrene (ABS)
Several considerations will determine viability of plastic repair procedure(s):
Is the damage cosmetic or structural?

Can the repair be carried out on the vehicle?
Is the part readily available?
Is component repair the most cost effective method?
Can the component be economically restored to original strength and appearance?
Will the repair provide for the fastest, highest quality repair?
Several types of plastic are in use for automotive application. However, all plastics will fall into 2 primary
categories of thermoplastic or thermosetting plastic.
Thermosetting Plastic
Generally, thermosetting plastics are made with 2-part thermosetting resins. When mixed together, heat is
generated, producing a cure that is irreversible. Because of this, thermosetting plastics will require the use of a
2-part adhesive for repair.
Sheet-Molded Composite (SMC) p>Sheet-Molded Composite (SMC) is a type of thermosetting plastic that uses
glass fibers or nylon fibers in combination with thermosetting polyester resins. When fully cured, SMC is strong
and rigid.
SMC is similar to, but not identical to, fiberglass. Ford Motor Company uses SMC in components such as
fenders, hoods and liftgates.
Thermoplastic Compounds
Thermoplastic compounds are manufactured by a process that is reversible. Thermoplastics can be remolded
repeatedly by reheating. This characteristic of thermoplastics makes plastic welding a possible repair
alternative. A repair of thermoplastic compounds is still possible through the use of 2-part adhesive and filler
repair materials and reinforcements as needed. Thermoplastics are widely used in interior trim components,
wheel flares, body side cladding and bumper covers.
Polyolefin
Polyolefins fall into the family of thermoplastics with one unique characteristic, an oily or waxy feel to the
material when sanded or ground. Polyolefin lends itself very well to remolding through the use of heat.
Liftgate Applique - Navigator 1085

Because of this, components made of this material lend themselves well to the possibility of plastic welding.
Most adhesive repair materials and paint will not bond to a surface of polyolefin unless an adhesion promoter
specially formulated for plastic is first applied to the exposed raw surface. Otherwise, polyolefins are repaired
like most other thermoplastics. Some typical uses of polyolefins are:
bumper covers.
fan shrouds.
wheel housings.
Correct identification of the various types of plastic is necessary to select the appropriate repair method(s) to
carry out high quality plastic repairs. Refer to Plastics Identification in this section.
Polyolefin 1086

Sealers
The correct sealing of joints is essential to repairing the vehicle correctly. Sealers are used to prevent wind
noise, water leaks, exhaust fumes and dust from entering the vehicle. They also provide anti-corrosion
barriers. Sealers are applied to areas such as door and rear compartment hem flanges, wheelhouse, quarter
outer, floor, cowl, roof and other panel-to-panel attaching points. The following joint sealers are
recommended for use depending upon the application:
Brushable Seam Sealer - A sealer intended to restore the original brushed seam appearance. It is used
to seal lap joints in sheet metal that are spot welded (for example, floorpans and cowls). Use a product
obtained locally.
Roof Ditch Sealer - A self-leveling sealer used for drip rails, roof seams, quarter panels to rear deck
and for water leaks.
Seam Sealer - Heavy-bodied, non-sag adhesive/sealer for use on standing cosmetic seams, truck bed
seams, tooled door skin seams and floor pans. Also used for water leaks and noise concerns.
Sealers should remain flexible after curing and must be paintable. Follow the manufacturer's directions for
correct application of these materials.
Any damage to originally sealed joints should be repaired by resealing. Along with attaching points of new
panels, open joints that require bridging of sealer to close a gap should be sealed using a heavy-bodied sealer.
Sealers 1087

Sound Deadeners and Insulators
NOTICE: Mastic is made of a combustible material and should be removed prior to carrying out
welding procedures to the area. Heat zones from welding near the mastic can cause the mastic material
to burn.
NOTICE: Corrosion protection must be restored to the area AFTER the mastic material is applied.
Corrosion protection products may be wax based and loss of adhesion may occur.
NOTE: The following illustrations serve as a reference to indicate mastic patch (butyl pad) locations.
Additional insulators and sound deadeners are used beyond those indicated in the illustration.
NOTE: To restore the vehicle to design intent, missing or damaged sound deadeners and insulators should be
replaced with the correct service replacement component.

1 16E098 Mastic insulator - fender(s)
2 16E096 Mastic insulator - fender(s)
3 11172 Mastic insulator - front floorpan
4 54344 Mastic insulators - roof
5 27786 Mastic insulators - wheelhouse
6 11530 Mastic insulator - rear floorpan
7 113B56 Mastic insulator - rear floorpan
8 11173 Mastic insulator - front floorpan
9 20356 Mastic insulator - door panel(s)
10 11180 Mastic insulator - floor tunnel
1. NOTE: In applications where mastic material is applied as a pumpable material at the factory,
replacement of missing or damaged mastic is acceptable in the form of cut-to-fit butyl pad(s) or
pumpable mastic material(s) when carrying out repairs.
Whenever replacement of an existing mastic insulator is carried out, the surface must be thoroughly
cleaned to make sure correct adhesion will occur. The surface should be 10C (50F) or greater before
applying the mastic. The use of a heat gun to warm the metal surface will aid in adhesion.
Sound Deadeners and Insulators 1088

Sound Deadeners and Insulators 1089


Welding Precautions - Steel
Material
Item Specification
Motorcraft Premium Undercoating PM-25-A -
Motorcraft Rust Inhibitor Aerosol PM-24-A -
General Specifications -Welding Specifications
Item Specification
Plug Weld Hole 8 mm (0.31 in)
Weld Wire ER70S-3 or equivalent 0.9-1.1 mm
(0.035-0.045 in)
General
Equipment
3 Phase
Inverter Spot
Welder
254-00002
Compuspot
700F Welder
190-50080
I4 Inverter
Spot Welder
254-00014
Inverter
Welder with
MIG Welder
254-00015
and skin use protection such as a welder's helmet with dark-colored filter lenses of the correct density.
Electric welding will produce intense radiation, therefore, filter plate lenses of the deepest shade
providing adequate visibility are recommended. It is strongly recommended that persons working in
the weld area wear flash safety goggles. Also wear protective clothing. Failure to follow these
Welding Precautions - Steel 1090

injury.
WARNING: On vehicles equipped with Safety Canopy options, prior to carrying out any
sectioning repairs near the roof line or sail panel areas of the vehicle, remove the Safety Canopy
module and related components. Failure to comply may result in accidental deployment or damage to
the Safety Canopy. Refer to Section 501-20B . Failure to follow these instructions may result in
serious injury to technin or vehicle occupant(s).
NOTICE: Disconnect the instrument cluster module, Powertrain Control Module (PCM), Engine
Control Module (ECM), fuel pump driver module (gas only), Anti-lock Brake System (ABS) module
and diesel Fuel Injection Control Module (FICM), if equipped. Electronic modules and related wiring
may be damaged when exposed to heat from welding procedures.
NOTE: When it is necessary to carry out weld-bonding procedures, refer to Weld-Bonding in this section.
The correct equipment and settings must be used when welding mild or high-strength steel. Metal Inert Gas
(MIG) and Squeeze-Type Resistance Spot Welding (STRW) are the preferred methods. Surfaces must be
clean and free of foreign materials.
Do not use gas welding equipment.

Adequate ventilation must be provided to avoid accumulation of poisonous gases.
A test weld should always be carried out on a test sample. Refer to the Weld Nugget Chart in
Specifications for Ford-approved weld nugget information.
Use cleaning brushes and abrasive grinding wheels dedicated to the type of materials being welded.
Follow the equipment manufacturer's prescribed procedures and equipment settings for the type of
welder being used. ER70S-2 or ER70S-6 wire are typically used for MIG welding steel.
Disconnect the battery(s). Refer to Section 414-01 .
Replace spot-welded components by spot welding where possible.
Corrosion protection must be restored whenever bare metal repairs are made. Refer to Restoring
Corrosion Protection Following Repair in this section.
Adequate power supply needs to be used to make sure of correct equipment performance.
Factory spot welds may be substituted with either STRW or MIG plug welds. Spot/plug welds should
equal factory welds in both location and quantity. Do not place a new spot weld directly over an
original weld location. Plug weld hole should equal 8 mm (0.31 in) diameter.
Components made of high-strength steel should not be heated to straighten or repair. If components
are severely bent or kinked, new components should be installed.
When MIG or arc welding frame components, the following guidelines should be followed:
NOTICE: When welding low carbon steel side rails (35,000 psi yield strength), emphasis should be
placed upon weld application techniques to avoid excessive heat affected zones that may adversely
affect frame operating stresses. When welding within 100 mm (3.93 in) of any crossmember that
contains rivets, remove the rivets and install new SAE grade 8 bolts/nuts.
NOTE: Do not weld on any reinforcement. Use compression type fasteners when attaching any component to
the frame in the reinforcement area.
A temperature indicating crayon calibrated below 650C (1,200F) should be used to avoid
overheating and weakening the metal.
Attach the ground clamp as close as possible to the work area.
Choose welding electrodes according to the type of steel, thickness and polarity of the arc welder AC
or DC.
Do not use water or compressed air to cool welding. This can cause the metal to become brittle and

weak.
Where frame wax coating and the bracket E-coat have been removed, apply anti-corrosion coating to
all affected surfaces of the frame, bracket and weld areas.
Clean the welded areas with a wire brush.
Use a wax and grease remover for a final cleaning of the weld areas.


Plastics Identification
injury.
NOTE: Identification of the various plastic types is necessary to select the appropriate repair methods to
make high quality plastic repairs. Plastics can generally be broken down into 2 categories, thermoplastics and
thermosetting plastics. Thermoplastics can be remolded by heating. This makes plastic welding a possible
repair alternative.
1. NOTE: In some instances, a code or material designation is stamped indicating the plastic type.
Thermoplastics are solvent reactive. Types of thermoplastics include Thermoplastic Olefin (TPO),
Polyvinyl Chloride (PVC) and Acrylonitrile Butadiene Styrene (ABS). Polyolefins have an oily or
waxy appearance. Examples include some bumper covers, stone shields, fender aprons and fan
shrouds. Polyolefins require an adhesion promoter prior to carrying out any refinish procedure.
To determine if the part is a polyolefin, grind the damaged area in an out-of-sight area.
Grinding a polyolefin will melt and smear the plastic and leave a ragged edge. If the part is
non-polyolefin, the area will grind or sand smoothly, producing a powdery dust.
Rigid Plastic Parts
Code Family Name Common Trade Name Typical Application

ABS Acrylonitrile Butadiene ABS, Cycolac, Lustran, A-Pillars, Consoles,
Styrene Kralistic Grilles
SMC Sheet Molded Composite SMC Body Panels
Flexible Plastic Parts
Code Family Name Common Trade Name Typical Application

RRIM Reinforced Reaction RRIM Fascias, Body Panels, Body
Injection-Mold Material Trims
PUR
TPO Thermoplastic Polyolefin Polytrope, Renflex, Bumpers, End Caps, Rubber
Santropren Telcar, Strips, Sight Shields,
Vistaflex, ETA, Apex, Claddings, Interior B-Post
TPO
Plastics Identification 1093

2. Polyolefin plastic can also be identified by placing a small sliver in a container of water, if the sample
floats, it is a polyolefin plastic. A non-polyolefin will sink when placed in a container of water.
3. Generally, thermosetting plastics are rigid or semi-rigid. Sheet-Molded Composite (SMC) is

reinforced with glass and other fibers and are strong and rigid. SMC is used for large panels such as
hoods, liftgates, fenders and quarter panels.
A burn test can be a reliable method to determine if a plastic is a thermosetting plastic.
Extreme care must be exercised when using this method.
NOTICE: The component must be isolated away from the vehicle and all
combustible materials to perform this test.
Apply an open flame to the corner of the damaged component. If the material
crystallizes and becomes hard, it is a thermosetting plastic.
Plastics Identification 1094


Plastics Refinishing
All Components
WARNING: Do not paint any air bag module trim covers or deployment doors. Paint may cause the
air bag to deploy incorrectly. Failure to follow this instruction may increase the risk of serious personal
NOTE: When using any Ford-approved refinishing product, it is recommended to stay within the same paint
system throughout the process. For example, do not use one manufacturer's primers and another
manufacturer's topcoats.
1. NOTE: Care must be used if applying heat to parts. Thermoplastics soften and tend to lose their
shape when heated.
The first step for any repair or refinish procedure is to identify the type of plastic. Is it thermosetting
or thermoplastic, grained or smooth? This will determine how it should be cleaned and prepared for
refinishing. For additional information, refer to Plastics Identification in this section.
It is essential that the correct cleaner is used, depending on which painting system is
employed, solvent-based or water-based.
Clean part with warm water/mild detergent, then with plastic cleaner to remove wax, silicone
and other contaminants. Do not allow parts to remain wet for extended periods.
As a general rule, if water beads on the part, it requires additional cleaning as all the
manufacturing release agents have not been removed.
2. New parts may require baking in a spray booth or heating with heat lamps to release trapped solvents
or mold release agents used in the manufacturing processes.
Non-grained components
3. After cleaning, lightly sand with 600-grit or finer sandpaper. Remove sanding residue with plastic
cleaner and wipe dry.
Grained components
4. After cleaning, light use of a gray scuff pad is permissible providing the graining not be flattened.
Remove sanding residue with plastic cleaner and wipe dry.
All components
5. Apply a plastics adhesion promoter to any bare plastic part following manufacturer's
recommendation. Throughout the refinish procedure, any time bare plastic is exposed for any reason,
it is essential that adhesion promoter be reapplied to that area.
6. A sealer may be required to prevent wrinkling and lifting of the topcoat prior to carrying out the
refinish procedure.
Plastics Refinishing 1095

7. Flexible and non-flexible components should be refinished separately as a flex additive may be
required when refinishing flexible parts (refer to the paint manufacturer's recommendation).
8. It is recommended to carry out refinishing of exterior components on-vehicle (after cut-in) to control
color match and blending to adjacent panels.
9. Proceed with the refinish process and follow the Ford-approved paint system procedures. Steps may
vary between paint manufacturers.
Plastics Refinishing 1096


Plastics Repair
Material
Item Specification
Plastic Bonding Adhesive -
TA-9
injury.
1. In deciding whether to repair or install a new component, follow these guidelines.

Is a part readily available?
Can the damaged part be economically returned to its original strength and appearance, or
will the labor cost exceed the cost of a new component?
Will repair provide for the fastest, highest quality repair?
2. NOTICE: Never apply solvents such as lacquer thinner or reducer at any stage of plastic repair.
Solvents, cleaners and water are absorbed by many types of plastics and by the glass fibers used
for reinforcements. If this occurs, the plastic may swell in the area of repair and cause the
repair to fail. Remove cleaners and water quickly and use air and heat to speed up dryg.
NOTICE: During the repair of many plastics and particularly polyolefin plastics, an adhesion
promoter must be applied to the substrate to allow repair materials and paint to bond correctly.
Reapplication is required when grinding or sanding through the sealer or primered layers.
NOTE: When possible, it is recommended to carry out as much of the plastic repair as possible on the
vehicle. Parts mounted on the vehicle are held in correct alignment throughout the repair. Attempting
to repair the part off the vehicle may cause misalignment. This could lead to failure of the repair.
Select the correct repair method by identifying the type of plastic being repaired. For additional
information, refer to Plastics Identification in this section to determine the type of plastic being
repaired.
3. NOTE: Always refer to the manufacturer's label directions for the type of repair materials, fillers and
bonding agents being used as they are material specific.
Determine whether a reinforcement piece is needed as a backer on large repairs.
Construct a reinforcement piece from a scrap piece of the type of plastic being repaired and
follow manufacturer's label directions for the type of system being used.
When repairing Sheet-Molded Composite (SMC), a reinforcement piece can be constructed
using several layers of glass cloth saturated with resin or structural adhesive. The weave of
the cloth or screening should be loose enough to allow the resin to thoroughly penetrate.
Reinforcement should cover the entire area of damage and extend outward beyond the
Plastics Repair 1097

damage or joint area.
Sheet-Molded Composite (SMC) Panel Repair
NOTE: The following procedure applies to repair of structural cracks and large gouges. If damage is
cosmetic, use of reinforcing cloth may not be necessary.
1. Panels to be repaired should be dry and at room temperature 18C (65F) to 24C (75F) prior to
carrying out any repairs. Both sides of the panel must be thoroughly cleaned before sanding or
grinding.
2. Cover the break in the SMC (front and back) with masking tape. This protects the damaged area from
absorbing the prep cleaner and eliminates wicking of the cleaner through the fibers into the SMC .
3. Remove all waxes, silicones, dirt and road oils from the area surrounding both sides of the damaged
area with a plastics wax and grease remover.
Remove the tape and sand the back of the repair area with an angle grinder, Dual Action
(D/A) sander or by hand using 80-grit sandpaper. Remove all dust with a vacuum and tack
cloth.
4. Create a reinforcing patch using a piece of scrap SMC that conforms well to the back of the damaged
area or form a patch from fiberglass cloth.
Cut a section of cloth large enough to cover the repair, plus 25.4 mm (1 in) around the repair
area.
Cut a section of plastic film backing approximately 25.4 mm (1 in) larger than the cloth. Lay
the plastic smooth, flat surface where it will be used to create a pyramid patch.
5. Follow manufacturer's directions and apply plastic repair adhesive to the plastic film backing and
smooth with plastic spreader to recommended thickness. Place the pre-cut fiberglass cloth on the
adhesive-coated plastic film. Cover the cloth with a coat of repair adhesive and spread to the
recommended thickness.
6. Apply the prepared patch to the backside of the panel and compress. Follow manufacturer's
instructions for adhesive cure. Remove plastic film after adhesive cures and sand as necessary to
remove roughness.
7. Remove masking tape from the front side of damaged area and grind down to the backing patch. Use
an angle grinder with a 30- to 40-grit wheel. Make a gradual taper in the area, this will prevent
bull's-eyes or read-through in the finished repair. Sand prepared area with a D/A sander or hand-sand
with 80-grit sandpaper.
8. Build a pyramid patch using fiberglass cloth or equivalent and plastic repair adhesive. Following
manufacturer's directions, apply patch to damaged area.
9. Rough-grind area to remove excess adhesive. Sand repair area with 80-grit sandpaper, making sure to
cut slightly below the SMC finished surface. This will allow for a finish coat of plastic body repair
material.
10. Apply a finish coat of plastic repair filler material per manufacturer's directions.
11. Finish-sand, prime and topcoat using Ford-approved paint systems.

Thermoplastic Compounds
1. In deciding whether to repair or install a new component, follow these guidelines.

Is a part readily available?
Can the damaged part be economically returned to its original strength and appearance, or
will the labor cost exceed the cost of a new component?
Will repair provide for the fastest, highest quality repair?
2. NOTE: The following steps are to be used as a guideline. Depending on what brand of adhesives or
patch materials are used, procedures may vary slightly.
Thoroughly clean the damaged area with wax and grease remover formulated for use with plastics.
3. Hand sand the repair area with 80-grit sandpaper and remove any foreign material with compressed
air.
4. Apply a plastics adhesion promoter per label directions to the repair area.
5. For small repairs, a plastic adhesive filler can be applied to the damaged area. Follow manufacturer's
directions and build layers to form a thickness above the damaged area. This will allow the area to be
sanded smooth.
6. To repair large holes or cracks, measure and cut a piece of fiberglass cloth or equivalent 25.4 mm (1
in) larger than the crack or hole.
Apply plastic repair adhesive to the damaged area and immediately apply fiberglass cloth into
plastic adhesive for reinforcement. Apply additional plastic repair adhesive for strength and
shape as required.
7. Contour and shape the repair as necessary with a D/A sander. Avoid sanding through the repair.
8. Finish-sand the area and carry out any required paint operations using Ford-approved paint systems.
Tab Repair - Bumper
1. NOTE: Inspect the bumper cover to determine if part of it can be repaired to an acceptable level of
quality of appearance, fit and durability. Will labor and material cost of the repair meet or exceed the
cost of a new replacement bumper cover? If the bumper cover is determined to be repairable, proceed
to the following steps.
NOTE: The following steps are to be used as a guideline. Depending on what brand of adhesives or
patch materials are used, procedures may vary slightly.
Remove the affected bumper. For additional information, refer to Section 501-19 .
NOTE: Illustration is not vehicle specific.
2. Clean the broken tab(s) with a plastics wax and grease remover.

3. Hand sand the repair area with 80-grit sandpaper and remove any foreign material with compressed
air.
4. Apply a plastics adhesion promoter per label directions to the repair area.
5. Measure and cut a patch of fiberglass cloth or equivalent large enough to form the front of the tab,
then slope back in a wedge shape approximately 51 mm (2 in) from original tab.


Refinishing - Environmental Damage
Material
Item Specification
Motorcraft Acid Neutralizer -
ZC-1-A
Motorcraft Alkaline Neutralizer -
ZC-2-A
3MTM Perfect-ItTM Show Car Liquid -
Wax
39026
Motorcraft Detail Wash -
ZC-3-A
Iron Oxide (Rail Dust) or Acid Rain Decontamination
injury.
NOTICE: In extreme cases of contamination, the vehicle may ng. To avoid paint failure, follow the
appropriate decontamination procedure prior to carrying out any panel refinishing procedure.
NOTE: Iron oxide contamination appears as tiny rust spots on horizontal surfaces and in severe cases can be
felt. This damage is typically caused from rail shipment, storage near railroad tracks or fallout from industrial
manufacturing facilities.
NOTE: Acid rain contamination can be identified as water spotting and, in severe cases, staining within the
water spots.
1. NOTICE: Never paint over iron particles as rust spots will reoccur. Use only the recommended
decontamination procedure detailed below.
Rinse any dust, dirt and foreign material from the vehicle body with cold water. Flush liberally.
2. Prepare the acid neutralizer by mixing 8 parts of water to 1 part neutralizer in a bucket.
3. NOTICE: To avoid paint failure, do not allow the product to dry on the vehicle.
NOTE: Use a separate wash mitt for each product applied to the vehicle.
Working quickly and beginning at the top of the vehicle and working to the sides, apply the acid
neutralizer mix to the entire vehicle. Keep the vehicle wet with the solution and lightly agitate for 5 to
Refinishing - Environmental Damage 1101

7 minutes. Continue around the vehicle 4 to 5 times. For severe conditions, work the product for up to
8 minutes.
4. Rinse the vehicle completely with cold water to remove the product.
5. Dry only the horizontal surfaces of the vehicle, do not dry the glass at this time.
6. NOTICE: To avoid damage to the paint surface, do not apply the alkaline neutralizer directly to
the vehicle plastic trim.
NOTE: Use a separate wash mitt for each product applied to the vehicle.
NOTE: Alkaline neutralizer is a ready-to-use product. Do not mix with water.
Pour the alkaline neutralizer into a squirt bottle and apply the solution to a clean wash mitt.
7. NOTICE: To avoid paint failure, do not allow the alkaline neutralizer to dry on the vehicle.
Apply the product to the vehicle keeping the solution wet and lightly agitate for 5 to 7 minutes. For
severe conditions, work the product for up to 8 minutes.
8. Rinse the vehicle completely with cold water to remove the product.
9. Prepare the detail wash by mixing 29.5 ml (1 oz) with 3.78L (1 gal) of water.
10. Using a clean wash mitt, shampoo the entire vehicle and rinse with cold water. Dry the vehicle
completely.
11. Visually inspect the paint surface for any remaining evidence of ferrous metal particles. Repeat
procedure as necessary.
Surface Finishing Following Decontamination
1. NOTICE: When attempting to affect a repair by buffing, polishing or color sanding, do not
remove an excess of 0.3 mil of paint film or refinishing will be required.
NOTE: Acid rain discoloring or etching may require color sanding in addition to buffing and
polishing. In extreme cases, refinishing may be required if the following procedure does not restore
the vehicle finish.
NOTE: Do not intermix buffing products. Use only one manufacturer's product.
NOTE: Always follow the manufacturer's product usage sequence. Use the appropriate buffing or
polishing pad at the recommended buffing speed as specified by the product manufacturer.
Apply rubbing compound to the vehicle surface as recommended by the product manufacturer.
2. Apply machine glaze to the vehicle surface as recommended by the product manufacturer.
3. Use an alcohol and water mixture (1 to 1) to clean the buffed and polished areas. Verify removal of
scratches and swirls before the application of the final polish.
4. Apply a final polish material by hand, with a dual-action sander and foam pad, or with an orbital

polisher and appropriate polishing bonnet.
5. Wash and dry the vehicle.


Refinishing - Manufacturing Damage
Material
Item Specification
3MTM Perfect-ItTM Show Car Liquid -
Wax
39026
Motorcraft Detail Wash -
ZC-3-A
injury.
NOTICE: To avoid overspray damage to adjacent panels, protect adjacent areas/substrates when
preparing for and during refinishing.
NOTE: Peeling/delamination concerns can be described as lack of adhesion, either between the substrate and
topcoats or between individual coats of paint.
1. Wash the repair area with detail wash or pH-neutralater.
2. Remove any trim, emblems and hardware from the area to be repaired.
3. NOTE: All delamination must be removed.
Sand or media blast the damaged surface, keeping the repair area as minimal as possible.
4. Treat any bare metal surface to prevent flash corrosion, and prime and block sand as necessary prior
to refinishing.
5. Mask the adjacent panels to protect from overspray.
6. Spot repair the base coat as necessary, following the paint manufacturer's prescribed procedures.
7. Following the paint manufacturer's prescribed procedure, apply clear coat to the entire panel.
Refinishing - Manufacturing Damage 1104

Refinishing - Manufacturing Damage 1105


Restoring Corrosion Protection Following Repair
Special Tool(s)
Rust Inhibitor Installation Kit

286-00002
Undercoating Spray Gun

286-00001
Material
Item Specification
Motorcraft Metal Surface Prep -
ZC-31-A
Premium Undercoating -
(aerosol)
Rust Inhibitor -
(aerosol)
injury.
NOTICE: Drilling access holes in body panels is not recommended. Drilling holes will break the original
paint finish and promote corrosion.
NOTE: Corrosion protection needs to be restored whenever it is necessary to sand or grind through painted
surfaces or E-coat, or when bare metal repairs are made.
NOTE: Refer to product label for preparation and handling instructions.
1. The surfaces must be free of oil, dirt and other foreign material. Carry out the process in the following
sequence.
1. Thoroughly clean and deetal surfaces using metal surface prep to remove wax and grease.
2. For best results, the vehicle should be at room temperature. Attach the rust inhibitor canister
to the Rust Inhibitor Installation Kit 286-00002.
3. Rust inhibitor should be applied after the welding and refinishing process. Product cannot be
welded through.
4. Air pressure setting for applicator gun is 448-517 kPa (65-75 psi).
Use the long wand when spraying enclosed areas. The spray nozzle provides a
360-degree spray pattern. Insert the wand as far as possible into the access hole, pull
Restoring Corrosion Protection Following Repair 1106

the trigger and wait 2-3 seconds and slowly pull the wand out of the access hole.
The short, hook-shaped wand sprays in one direction and must be rotated to provide
complete coverage.
Apply the material in light mist coats.
Material displaces moisture.
5. Clean up any overspray with a mild solvent such as mineral spirits or bug and tar remover.
NOTE: The following illustrations provide typical applications of body seams and spot welded flanges and
are not vehicle specific.
2. NOTE: Door assembly lower view.
Apply rust inhibitor as shown to the inside of the door shell on all the interior metal surfaces using the
most suitable applicator wand. Apply material to the exposed edges after carrying out the welding
process. Make sure horizontal surfaces are well protected as they are more susceptible to corrosion.
Keep door drain holes clear to prevent moisture buildup.
3. NOTE: Quarter panel inner view.
Apply rust inhibitor to the closed channel portion of the spot weld flange areas using the short,
hook-shaped wand. Apply material to the exposed edges after carrying out the welding process. Make
sure horizontal surfaces are well protected as they are more susceptible to corrosion.
4. NOTE: Door frame opening view.
Apply rust inhibitor to the closed channel portion of the spot weld flange areas using the short,
hook-shaped wand. Make sure horizontal surfaces are well protected as they are more susceptible to
corrosion.

Body and Frame Undercoating
1. WARNING: Always refer to Material Safety Data Sheet (MSDS) when handling chemicals
and wear protective equipment as directed. Examples may include but are not limited to
respirators and chemically resistant gloves. Failure to follow these instructions may result in
WARNING: Always wear protective equipment including eye protection with side shields,
and a dust mask when sanding or grinding. Failure to follow these instructions may result in
NOTICE: Do not allow undercoating on powertrain components. Failure to follow these

instructions may result in incorrect operation of these components.
NOTE: Avoid high-pressure water spray cleaning to treated underbody area for 24 hours.
Wire brush the area and make sure the surfaces are free of oil, dirt and other foreign material. Carry
out the undercoating process in the following sequence.
1. Thoroughly clean and degrease metal surfaces using metal surface prep to remove wax and
grease.
2. For best results, the vehicle should be at room temperature.
Canister attaches directly to the dispensing gun. Attach the undercoating canister to
the Undercoating Spray Gun 286-00001.
3. Undercoat should be applied after the welding and refinishing process. Product cannot be
welded through.
4. Air pressure setting for applicator gun is 552-621 kPa (80-90 psi).
Apply light mist coats, applicator sprays in fogging pattern.
Material displaces moisture.
5. Clean up any overspray with a mild solvent such as mineral spirits or bug and tar remover.
NOTE: The following illustrations provide typical applications to frame rails and are not vehicle specific.
2. NOTE: Frame rail exterior spot-weld flange view.
Apply undercoat material to the exterior exposed edges after carrying out the welding and refinishing
process.

3. NOTE: Cross section view of typical unibody frame rail shown.
Apply rust inhibitor to the inner surfaces of the rail after carrying out welding process. Use the long
wand and insert as far as possible, depress trigger and wait 2-3 seconds and slowly pull the wand to
make sure the area is completely fogged.
4. NOTE: Full frame vehicle, front rail-to-mid rail section repair shown.
Apply undercoat material to the exposed surfaces after carrying out the welding process. Make sure to
completely cover any bare metal areas.



Sectioning Guidelines
General Equipment
3 Phase Inverter Spot Welder 254-00002

Compuspot 700F Welder 190-50080
I4 Inverter Spot Welder 254-00014
Inverter Welder with MIG Welder 254-00015
Material
Item Specification
(aerosol)
Rust Inhibitor -
(aerosol)
Seam Sealer -
TA-2
Structural Foam (Medium) -
Fusor 1908; obtain locally
NOTE: Observe prescribed welding procedures when carrying out any body side section repair. For
additional information, refer to Welding Precautions - Steel in this section.
NOTE: Illustration cut-lines are approximate. Illustration is intended as a guideline.
Structural Foam Insert Location
density. Electric welding will produce intense radiation, therefore, filter of the deepest shade providing
Sectioning Guidelines 1111

adequate visibility are recommended. It is strongly recommended that persons working in the weld
area wear flash safety goggles. Also wear protective clothing. Failure to follow these instructions may
injury.
serious injury to technician or vehicle occupant(s).
WARNING: Do not cut or grind body side components within 50 mm (1.96 in) of restraint
anchoring points. Welding within 50 mm (1.96 in) of restraint anchoring points may result in incorrect
operation of restraint devices. For additional restraints anchoring location information, refer to Section
501-20A and Section 501-20B . Failure to follow these instructions may result in serious injury to
NOTICE: Electronic modules and related wiring can be damaged when exposed to heat from welding
procedures. Carefully disconnect and remove, or position away from heat affected areas.
NOTE: Structural foam and a nylon carrier are contained in the lower D-pillar area, RH and LH side. The
nylon carrier is located between the D-pillar inner and outer panel. When repairing, not replacing body sheet
metal and the structural foam parts appear to be damaged, the area must be full-filled. This will encase
reinforcement parts or cracked foam in place and eliminate potential rattles. When carrying out a full-fill
application, up to 13 structural foam cartridges may be required to completely fill the cavity depending on the
level of damage to the area. When installing a new nylon carrier only, 3 structural foam cartridges are
required. This procedure should be carried out after sheet metal work has been completed and before final
painting of the vehicle.

1 41017 LH/ 41016 RH Nylon carrier
2 27865 LH/ 27864 RH Bodyside inner panel
Structural Foam Insert Location 1112

NOTE: Factory spot welds may be substituted with either Squeeze-Type Resistance Spot Welding (STRW)
or Metal Inert Gas (MIG) plug welds. Spot/plug welds should equal factory welds in both location and
quantity. Do not place a new spot weld directly over an original weld location. Plug weld hole should equal 8
mm (0.31 in) diameter.
NOTE: The following steps incorporate steps for carrying out the removal of bodyside outer panel(s) as well
as the structural foam and nylon carrier installation.
1. NOTE: When it is necessary to carry out weld-bonding procedures, refer to Weld-Bonding in this
section.
Corrosion protection needs to be restored whenever it is necessary to sand or grind through painted
surfaces or E-coat, or when bare metal repairs are carried out. For additional information, refer to
Restoring Corrosion Protection Following Repair in this section.
Make sure horizontal joints and flanges are correctly sealed with seam sealer to prevent
moisture intrusion. Water and moisture migrate to horizontal joints and corrosion tends to
occur more rapidly in these areas. Metal surfaces must be clean and dry before applying seam
sealer.
2. Drill out the spot welds of the damaged panel to be sectioned. Using a cut-off wheel, reciprocating
saw or plasma cutter, cut through the damaged area of the outer panel only and remove the section to
be replaced.
3. When welding overlapping surfaces or substrates, apply a weld-through primer between the surfaces
prior to welding.
4. Use duct or masking tape to close in the open bottom of the nylon carrier.
Insert and push the nylon carrier upward from the bottom of the vehicle to lock in the space
between the D-pillar inner and outer panel.
5. Install and weld in the sheet metal stuffer plate below the nylon carrier.
6. Insert one 140 mm (5.51 in) x 100 mm (3.93 in) x 75 mm (2.95 in) soft foam block into the No. 4
body mount area (oval hole inside the levitate area). The front edge of the block should be outboard
toward the D-pillar. The block will prevent foam expansion into the body mount.
7. Apply aluminum duct tape to cover all holes on the inside of the body and under side of the body in
the repair area.

8. Prepare the structural foam cartridges for application by warming with a heat gun or similar method to
obtain a working temperature of 46C (115F) to 74C (165F). This will allow for easier foam flow
from the cartridges. A pneumatic or manual application gun can be used.
9. Dispense the foam into the lower D-pillar through the large rectangular hole in the tail light opening.
Allow the foam to cure for 15 minutes and remove the aluminum tape as necessary.
10. Refinish the repair area as required using Ford-approved paint procedures. When the surfaces have
been refinished, apply corrosion proton material as required.


Weld-Bonding
General Equipment

Material
Item Specification
Metal Bonding Adhesive -
TA-1
(aerosol)
Rust Inhibitor -
(aerosol)
Seam Sealer -
TA-2
Weld-Bonding - Squeeze-Type Resistance Spot Welding (STRW) Method
density. Electric welding will pse radiation, therefore, filter plate lenses of the deepest shade providing
Weld-Bonding 1115
injury.
or E-coat, or when bare metal repairs are made. For additional information, refer to Restoring Corrosion
Protection Following Repair in this section.
NOTE: On door shells that are manufactured with structural adhesives only, weld bonding door skins is not
recommended. Only metal bonding adhesive should be used.
NOTE: Weld-bonding is a method used to join metals using Squeeze-Type Resistance Spot Welding (STRW)
or Metal Inert Gas (MIG) and structural adhesive. The steps listed in this procedure apply to both types of
welding. STRW is the preferred method. MIG welding should only be used when areas to be welded cannot
be accessed using STRW -type machinery.
NOTE: Factory spot welds should be substituted with STRW or MIG welds. Spot/plug welds should equal
factory welds in both location and quantity. Do not place a new spot weld directly over an original weld
location. Plug weld hole should equal 8 mm (0.31 in) diameter.
1. Verify the vehicle is dimensionally correct on a frame machine. Straighten if necessary.
2. Remove damaged panels with an air saw or air chisel. Remove only large portions of the damaged
panel. Avoid cutting into mating flanges or adjacent parts.
3. Drill out the spot welds using an appropriate spot-weld cutter and remove the remaining portions of
the panel to be replaced.
4. Prepare any damaged flanges on the vehicle using a hammer and a dolly.
5. Grind the mating surface of the original flanges not greater than 25 mm (0.98 in) where the metal
bonding adhesive will be applied.
Be sure to remove galvanizing on metal. Metal should have a shiny appearance.
Be careful not to damage the corners or thin the metal. The E-coat should also be removed on
the opposite side of the flange only where the spot welds are to be placed.
6. Dry-fit and clamp the replacement service parts to verify a correct fit.
Remove the service part after verifying correct fit and alignment.
7. NOTE: The ends of welding clamps should be insulated on the ends using tape or similar material
when welding is carried out.
Follow manufacturer's prescribed welding procedures and settings. For additional information, refer
to Welding Precautions - Steel in this section.
8. Prepare the adhesive. Dispense a small amount of metal bonding adhesive from the cartridge to make
sure of an even flow of both components. Attach the mixing tip and dispense a mixing tip length of
adhesive to make sure of a correct mix ratio.
9. NOTE: Welding can be carried out anytime during the adhesive curing process or after the adhesive
is fully cured. Welder settings will vary when welding through wet adhesive versus welding through
fully cured adhesive. Refer to welder manufacturer's recommended ttings for welding through fully
cured adhesive. It is recommended to place a shunt weld in an area with no adhesive to make sure of
conductivity, particularly when welding through fully cured adhesive.
Weld-Bonding 1116
Create a test sample.
1. Prepare the metal and adhesive as described. Apply a 6-9 mm (0.23-0.35 in) bead of adhesive
and weld the sample.
2. Place the welded sample in a vise and carry out destructive weld tests by peeling the scrap
metal apart using large lock-type pliers. Measure the weld nugget to determine that the nugget
meets Ford weld nugget requirements. If the weld nugget does not meet required size, adjust
welder settings until the correct weld nugget size is achieved.
3. When the correct weld nugget size is achieved, the service part can be weld-bonded. For
additional information, refer to Specifications in this section.
10. Apply a 6-9 mm (0.23-0.35 in) bead of metal bonding adhesive to the vehicle prepared flange surface.
11. Place the service part(s) in the correct position on the vehicle.
When positioned, do not pull the component away from the vehicle. If repositioning is
necessary, slide the service part(s). This will make sure of correct contact between the
components and adhesive.
12. Clamp evenly and tightly. The adhesive contains glass beads which will prevent over-clamping the
component.
13. NOTE: If welding will not be carried out immediately, allow a minimum of 1.5 to 2 hours of
adhesive cure time at 21C (70F) before removing clamps. Cure time at lower temperatures should
be increased. Clamps may be removed immediately after the component is welded.
Wipe excess adhesive from the panel before it cures.
-96. Finish any cosmetic section seams with fiber-filled body filler. Rough sand the filler, after the
adhesive cures, apply conventional body filler and block-sand the area.
15. Use seam sealer wherever a cosmetic seam sealer is required.
16. Mix and apply primer surfacer per paint manufacturer's recommendations.
17. Mix and apply basecoat per Ford-approved paint recommendations.
18. Mix and apply clearcoat per Ford-approved paint recommendations. Refinishing materials may be
force-dried following paint manufacturer's recommendations.
19. Apply corrosion protection to the repair area as required.
Weld-Bonding - Metal Inert Gas (MIG) Welding Method
Weld-Bonding 1117
injury.
NOTE: MIG weld-bonding can be substituted as an alternative to STRW . It may only be used to weld areas
that are inaccessible to STRW machinery. However, when accessible, STRW is the preferred method.
or E-coat, or when bare metal repairs are made. For additional information, refer to Restoring Corrosion
Protection Following Repair in this section.
NOTE: On door shells that are manufactured with structural adhesives only, weld-bonding door skins is not
recommended. Only metal bonding adhesive should be used.
NOTE: Factory spot welds should be substituted with STRW welds or MIG plug welds. Spot/plug welds
should equal factory welds in both location and quantity. Do not place a new spot weld directly over an
original weld location. Plug weld hole should equal 8 mm (0.31 in) diameter.
1. Remove damaged panels with an air saw or air chisel. Remove only large portions of the damaged
panel. Avoid cutting into mating flanges or adjacent parts.
Drill out the spot welds using an appropriate spot-weld cutter and remove the remaining
portions of the panel to be replaced.
2. After removing the damaged sheet metal panel(s), repair any damaged flanges on the vehicle using a
hammer and dolly.
3. Using an appropriate grinder, carefully grind around the entire receiving flange area following the
original welds. Be sure to remove all E-coat, paint or galvanized coating from the mating surfaces of
the joint.
Be sure to remove galvanizing on metal. Metal should have a shiny appearance.
Be careful not to damage the corners or thin the metal. The E-coat should also be removed on
the opposite side of the flange only where the spot welds are to be placed.
4. Repeat Step 3 on the mating surface of the replacement service part(s).
5. Prepare the new service panel for plug welds.

Using the original panel as a reference, drill or punch 8 mm (0.31 in) diameter holes in the
exact number as the original spot welds. The holes should be positioned as close as possible
to the original spot weld locations, without lining up exactly on top of an original spot weld
site.
To make sure of correct weld performance, grind the immediate perimeter of plug weld hole.
Grind only in the area of the plug weld, this will keep corrosion to a minimum.
6. Dry-fit and clamp the replacement service parts to verify a correct fit and alignment.
Remove the service part after verifying correct fit and alignment.
7. The vehicle prepared flange areas where plug welds will be located must be kept free of adhesive.
Apply 25 mm (0.98 in) tape to the plug weld areas to prevent contamination from the adhesive.
8. Prepare the adhesive. Dispense a small amount of metal bonding adhesive from the cartridge to make
sure of an even flow of both components. Attach the mixing tip and dispense a mixing tip length of
Weld-Bonding 1118
adhesive to make sure of correct mix ratio.
9. NOTE: Refer to product label for preparation and handling instructions.
Apply a 6-9 mm (0.23-0.35 in) bead of adhesive to the vehicle prepared flange surface. Remove the
tape from the plug weld areas.
10. Place the service part(s) in the correct position on the vehicle.
When positioned, do not pull the component away from the vehicle. If repositioning is
necessary, slide the service part(s). This will make sure of correct contact between the
components and adhesive.
11. Clamp evenly and tightly. The adhesive contains glass beads which will prevent over-clamping the
component.
12. NOTE: Welding can be carried out anytime during the adhesive curing process or after the adhesive
is fully cured.
NOTE: If welding will not be carried out immediately, allow a minimum of 1.5 to 2 hours of
adhesive cure time at 21C (70F) before removing clamps. Cure time at lower temperatures should
be increased. Clamps may be removed immediately after the component is welded.
Wipe excess adhesive from the panel before it cures.
13. Finish any cosmetic section seams with fiber-filled body filler. Rough sand the filler, apply
conventional body filler after the adhesive cures and block-sand the area.
14. Use seam sealer wherever a cosmetic seam sealer is required.
15. Mix and apply primer surfacer per paint manufacturer's recommendations.
16. Mix and apply basecoat per Ford-approved paint recommendations.
17. Mix and apply clearcoat per Ford-approved paint recommendations. Refinishing materials may be
force-dried following paint manufacturer's recommendations.
18. Apply corrosion protection to the repair area as required.
Weld-Bonding 1119
Weld-Bonding 1120

Door Outer Panel
Special Tool(s)
Heat Gun
107-R0300
Heat Treatment Induction Resistance Spot

Welder
254-00001
Material
Item Specification
Flexible Foam Repair -
locally
TA-1
Rust Inhibitor -
(aerosol)
Seam Sealer -
TA-2
Door Assembly
NOTE: Door intrusion beam is constructed of Boron steel and is non-serviceable.

1 20125 LH/ 20124 RH Door assembly - mild and boron steel
2 20201 LH/ 20200 RH Door outer panel - mild steel
Door Outer Panel 1121

adversely aral integrity and crash safety performance, which could result in serious personal injury to
vehicle occupants in a crash.
injury.
1. Remove the outside door handle and mirror assembly. For additional information, refer to Section
501-09 .
2. Remove the outer door trim, including mouldings and weatherstrips.
3. Remove the door assembly and secure on a workstand.
4. NOTICE: Use care when drilling out spot welds to avoid drilling through door shell assembly
and damaging the door shell.
Using a spot weld cutter or equivalent, locate and drill out the spot welds on the door panel.
5. NOTICE: Use extreme care to avoid cutting the door shell or inner belt reinforcement and
damaging the door shell assembly.
Using a disc grinder, grind along the perimeter of the outer door panel hem to separate the hem edges
as indicated in the illustration.
6. NOTE: The use of a Heat Gun may aid in softening the door panel adhesive.
Prior to removing the outer panel, use a sharp knife to cut the adhesive between the door outer panel,
beltline reinforcement and intrusion beam.
Door Assembly 1122

Using a flat-blade chisel or equivalent, remove the original panel.

Using a sharp knife or broad edge scraper, remove the remaining portion of the hem flange
from the door shell.
Remove any remaining adhesive from the door shell flange.
7. Trial fit the service replacement panel to the door shell assembly.
8. Prepare the service replacement panel joint areas by sanding clean all mating surfaces.
9. Prepare the door shell assembly by grinding all the mating surfaces including the inner hem and outer
belt reinforcement and the intrusion beam.
10. Apply metal bonding adhesive to the following areas: service replacement hem flange, and outer belt
reinforcement-to-outer panel.
11. Position and align the new door outer panel to the door shell assembly, carefully turn the assembly
over and begin the hemming process.
Using a door panel installation tool or the hammer and dolly method, close the perimeter door
hem and smooth any residual adhesive in the joints.
12. Temporarily install the door assembly on the vehicle to verify correct alignment and fit.
13. Apply 2 to 3 spot welds to hold the door panel in position on the door assembly.
14. Place the door assembly back on a workstand and weld the door, replacing the original spot welds,
using a Squeeze-Type Resistance Spot Welding (STRW) machine. Finish grind as necessary and trial
fit the upper beltline moulding and mirror.
15. Prime and apply seam sealer in the lower hem flange area.
16. Prime and paint the door using Ford-approved paint system.
17. Apply NVH foam, locally obtained, to the intrusion beam and upper belt reinforcement areas of the
door assembly to maintain original equipment performance.
18. Apply rust inhibitor inside the door to all hem areas and upper beltline area. For additional
information, refer to Restoring Corrosion Protection Following Repair in this section.
19. Reassemble and install door and align. For additional information regarding door fitment
specifications, refer to Body in this section.
Door Assembly 1123

Door Assembly 1124


Frame Members
General Equipment

Material
Item Specification
ZC-31-A
(aerosol)
Rust Inhibitor -
(aerosol)
Front Frame Rail

1 5D059 LH/ 5D058 RH Frame rail sectioning/instruction kit
Frame Members 1125

injury.
NOTICE: The following is step-by-step procedure for carrying out front frame horn replacement on
Expedition/Navigator models. The Expedition/Navigator is a body on frame vehicle which is designed
with energy absorbing features in the front frame horns to manage crash energy. The horn section of
the frame MUST NOT be straightened if any holes or surfaces show evidence of collapse or buckling. If
any evidence of damage exists BEHIND the first frame crossmember in terms of buckling or cracking,
then the ENTIRE frame must be installed new.
NOTICE: Electronic modules and related wiring may be damaged when exposed to heat from welding
NOTE: Prior to beginning this procedure, the vehicle must be restored to its correct overall dimensions. For
additional information, refer to Body in this section for dimensional information.
NOTE: The replacement front frame horns are production parts designed with a taper to insert into the
mid-rail section to assist in alignment and welding operations. Tow hooks are not included with the
replacement frame kit.
NOTE: Corrosion protection needs to be restored whenever it is necessary to sand or grind through painted
surfaces or E-coat, or when bare metal repairs are made. For additional information, refer to Restoring
Corrosion Protection Following Repair in this section.
NOTE: Observe prescribed welding procedures when carrying out repairs to the frame assembly. For
additional information, refer to Welding Precautions - Steel in this section.
1. Position the vehicle on a frame rack following the manufacturer's recommendations. Measure the
vehicle to determine body and frame alignment. Rer to Body in this section for dimensional
information.
2. Remove the front bumper. For additional information, refer to Section 501-19 .
If equipped, remove tow hooks.
3. Unbolt the Front End Sheet Metal (FESM) and body mount bolts. If necessary, raise the body off the
frame assembly. For additional information, refer to Section 502-02 .
4. Locate the vertical weld line of the front frame horn to center mid-rail.
Front Frame Rail 1126

5. NOTICE: DO NOT cut directly along the weld line. Leave enough material on the forward side
of the weld line to allow the edge to be ground back exactly to the weld line. This is required to
assure a correct fit up between the frame and the replacement section.
Using a plasma cutter, reciprocating saw or die-grinder, remove the damaged front frame horn
section.
6. NOTICE: Do not thin out the frame rail. The material must maintain a minimum thickness of
3.1 mm (0.12 in) after grinding. This is required to maintain correct energy management in the
event of a collision.
Grind off the excess welding material that remains in front of the weld line on the frame mid-rail.
7. Remove the remaining portion of the front frame horn (ring-like piece) from inside the mid-rail with
pliers or similar tool.
8. Using a wire brush or sandpaper, remove the E-coat 15 mm (0.59 in) to 20 mm (0.78 in) wide from
the inner and outer surfaces of the existing mid-rail. Clean the surfaces with a wire brush and metal
surface cleaner.
Apply a zinc-rich, weld-through primer to the exposed inner and outer mating surfaces.
9. Using a wire brush or sandpaper, remove the E-coat 15 mm (0.59 in) to 20 mm (0.78 in) wide from
the inner and outer surfaces of the replacement frame horn section. Clean the surfaces with a wire
brush and metal surface cleaner.
Apply a zinc-rich, weld-through primer to the exposed inner and outer mating surfaces.

10. Install the front section inside the frame mid-rail. Support the replacement frame horn in position.
Verify that the FESM mount bracket lines up with the sheet metal hole. The holes should line up so
that the FESM mount can be replaced and the FESM mount bolt can be installed.
11. Make sure that the frame and service replacement part have attained a minimum room temperature of
10C (50F) before beginning the weld procedure. A Metal Inert Gas (MIG) welder capable of
producing 185-250 amps must be used. Use ER70S-3 or ER70S-6 weld wire 0.9-1.1 mm (0.035-0.043
in) diameter that is compatible with SAE 1010 steel. Shielding gas must be 100% carbon dioxide or
75% carbon dioxide and 25% argon.
12. Tack weld the frame horn replacement section into the existing frame at 4 small points centered on
the flats between the corners. This will hold the section in place to check the fit up prior to completely
welding up the section.
Measure the frame to make sure factory dimensions are maintained.
13. Make sure the frame section replacement is correctly aligned.

Carry out the remainder of the welding procedure.
After welding is complete, grind off any excess weld material.
14. Use a dye penetrant to determine if any cracks or large voids exist in the weld joint after the welding
process has been completed.
If any cracks or other defects exist, grind out the defect and repair it until the imperfection is
corrected.
15. Clean the repaired area(s) and any exposed metal surfaces. Restore corrosion protection to the
exposed surfaces of the repaired area(s) using anti-corrosion coating on exposed interior and exterior

surfaces.
16. Install the components removed during the repair procedure and torque fasteners to the correct
specification.


Inner Body Reinforcing Panels
General Equipment

Material
Item Specification
(aerosol)
Rust Inhibitor -
(aerosol)
Seam Sealer -
TA-2
Exploded View

1 02501 LH/ A-pillar upper reinforcement - mild steel
02500 RH
2 513A31 LH/ Roof side rail assembly - mild steel
513A30 RH
3 27865 LH/ Body side inner panel - mild steel
27864 RH
4 B-pillar reinforcement - mild steel
Inner Body Reinforcing Panels 1130

27841 LH/
27840 RH
5 24301 LH/ B-pillar inner - High-Strength Low Alloy (HSLA)
24300 RH 350 and Bake Hardened Steel (BH) 280 steel
6 22843 LH/ A-pillar reinforcement - mild steel
22842 RH
Cowl Side Panel to A-Pillar
and skin. Always use prolder's helmet with dark-colored filter lenses of the correct density. Electric
welding will produce intense radiation, therefore, filter plate lenses of the deepest shade providing
injury.
serious injury to technician or vehicle occupant(s)./b>
WARNING: Do not cut or grind body side components within 50 mm (1.96 in) of restraint
anchoring points. Welding within 50 mm (1.96 in) of restraint anchoring points may result in incorrect
operation of restraint devices. For additional restraints anchoring location information, refer to Section
501-20A and Section 501-20B . Failure to follow these instructions may result in serious injury to
NOTE: When carrying out repairs to the A-pillar area, the fastener shown in the illustration is used in place of
a structural weld. It is mandatory to install and torque the fastener to correct specification. RH view shown.
Exploded View 1131


1 W701823 Screw and washer
2 02039 LH/ 02038 RH Cowl side panel
Front Structure
Part
1 16274C Inner fender reinforcement rail
assembly - High-Strength Low
Alloy (HSLA) 350 steel
2 16274B Body inner fender
reinforcement - mild steel
3 02015 Cowl top outer panel - mild
steel
4 02030 Cowl lower panel - mild steel
5 01610 Dash panel - laminated steel
6 16275C Inner fender reinforcement rail
assembly - HSLA 350 steel
7 16275B Body inner fender
reinforcement - mild steel
8 16138 Radiator support - magnesiur 9 16139 Lower radiator
valign="top"> support - HSLA
350 steel
Underbody - Front Floor
NOTE: The front floor pan and reinforcements are common to all models.
Cowl Side Panel to A-Pillar 1132

Part
1 11135 Floor pan assembly - mild steel
2 10684 Crossmember assembly - mild steel
3 10414 Dash panel stiffener - High-Strength Low Alloy
(HSLA) 350 steel
Underbody Center and Rear Floor - Standard Wheelbase
Part
1 10110 RH Floor side member assembly
- High-Strength Low Alloy
(HSLA) 250 and mild steel
2 11215 Floor pan assembly - mild 3 11323 Reinforcement
steel panel - mild steel
4 10928 Reinforcement panel - HSLA
350 steel
5 10111 LH Floor side member assembly
- HSLA 250 and mild steel
Underbody Center and Rear Floor - Extended Wheelbase
Item Description
Underbody - Front Floor 1133

Part
Number
1 10110 RH Floor side member assembly - High-Strength Low Alloy
(HSLA) 250 and mild steel
2 11215 Floor pan assembly - mild steel
3 11323 Rear floor sill panel - mild steel
4 - Reinforcement (part of 11215)
5 112A18 Frame assembly - HSLA 250 steel
6 10456 Floor side members - HSLA 250 steel
7 10928 Reinforcement panel - HSLA 250 steel
8 10111 LH Floor side member assembly - HSLA 250 and mild steel
9 10928 Reinforcement panel - HSLA 250 steel
10 10120 Floor side members - HSLA 250 steel
personal injury le occupants in a crash.
procedures. Carefully disconnect and remove, or position away from heat affected areas. For additional
information, refer to Welding Precautions - Steel in this section.
NOTE: When it is necessary to carry out weld-bonding procedures, refer to Weld-Bonding in this section.
1. Remove the outer body sheet metal from the affected area prior to carrying out any body side
reinforcing panel replacement. For additional information, refer to Sectioning Guidelines in this
section.
NOTE: Factory spot welds may be substituted with either resistance spot welds or Metal Inert Gas (MIG)
plug welds. Spot/plug welds should equal factory welds in both location and quantity. Do not place a new spot
weld directly over an original weld location. Plug weld hole should equal 8 mm (0.31 in) diameter.
2. Remove the outer body sheet metal from the affected area prior to carrying out any reinforcinganel
replacement. For additional information, refer to Sectioning Guidelines in this section.
3. When welding overlapping surfaces or substrates, apply a weld-through primer between the surfaces
prior to welding. When the surfaces have been welded, apply corrosion protection material to the
surfaces or substrates. For additional information, refer to Restoring Corrosion Protection Following
Repair in this section.
4. Where possible, create a backer piece using a portion of the old panel. This will create a stronger
joint.
5. Appropriate seam sealer needs to be applied to exposed joints and seams in addition to corrosion
protection, particularly horizontal surfaces where moisture collects and migrates. Exposed seams and
joints can corrode or rust prematurely if seam sealer is not applied correctly. Clean surfaces with
metal surface prep or equivalent prior to applying seam sealer. For additional information, refer to
Underbody Center and Rear Floor - Extended Wheelbase 1134

Sealers in this section.
6. Proceed with the refinish process following paint manufacturer's recommendations. Apply rust
inhibitor or undercoating material to the repair area as required. For additional information, refer to
Restoring Corrosion Protection Following Repair in this section.
Underbody Center and Rear Floor - Extended Wheelbase 1135


Roof Panel
Special Tool(s)
Heat Gun
107-R0300
Heat Treatment Induction Resistance Spot

Welder
254-00001
Pro 230 MIG Welder
208-00030
General Equipment

Material
Item Specification
Flexible Foam Repair -
locally
TA-1
Roof Ditch Sealer -
Fusor 122EZ, 3MTM 08307
Seam Sealer -
TA-2
Roof Exploded View
Item Part Description
Roof Panel 1136

Number
1 50202 Roof panel - mild steel
2 41304 Rear roof rail reinforcement - mild steel
3 50222 Reinforcement - High-Strength Low Alloy (HSLA) 250
steel
4 5022 Reinforcement - HSLA 250 steel
7 03418 Windshield header - HSLA 350 steel
Removal
injury.
NOTICE: Be sure to adequately protect all glass, exterior finish and interior trim to avoid surface
contamination from repair materials.
1. Remove the luggage rack (if equipped).
2. Remove the windshield. For additional information, refer to Section 501-11 .
3. Remove the liftgate. For additional information, refer to Section 501-03 .
5. Remove the safety canopy from driver and passenger side. For additional information, refer to Section
501-20B .
6. Remove the roof opening panel glass (if equipped). For additional information, refer to Section
501-17 .
Roof Exploded View 1137

7. Remove the quarter panel glass panels. For additional information, refer to Section 501-11 .
8. Remove the sealer from the roof ditch and the rear roof panel flange, using a sharp putty knife or
equivalent.
9. NOTE: The use of a Heat Gun may aid in softening the sealer and adhesive. Do not overheat.
From inside the vehicle, leaving as much of the foam as possible intact, separate the NVH foam,
sealer and adhesive along the roof bows from the roof panel, using a flexible and sharp broad scraper
or knife.
10. Remove (drill out) all the roof panel spot welds from the windshield, rear liftgate header and roof
ditch areas.
11. Using a die grinder, carefully cut along the upper flange of the roof panel, the entire length of the
panel.
12. With the help of an assistant, remove the roof panel from the vehicle.
13. Using an air hammer equipped with a panel cutter bit, carefully separate the remaing portion of the
roof panel from the vehicle by cutting along the inner portion of the roof ditch area.
Installation
NOTICE: To avoid inadvertent damage, be sure to adequately protect all glass, exterior finish and
interior trim.
1. Using a hammer and dolly, straighten any damage caused to flange areas during removal.
2. Using a grinder, carefully prepare the roof ditch area for the new roof panel.
3. With the help of an assistant, position the new roof panel on the vehicle.
4. Correctly align and index-mark the positioning of the panel-to-vehicle and remove the panel.
5. Apply metal bonding adhesive to the roof reinforcements, following label instructions.
6. Apply a bead of flexible foam (locally obtained) directly to the NVH foam remaining on the roof
bows and immediately reinstall the roof panel aligning it to the index marks made during the test
fitting.
7. Reinstall the roof panel aligning it to the index marks made during the test fitting. If adjustment is
necessary, do not lift the roof panel, slide to reposition. Make sure good contact is made with the
sealer and adhesive and carefully clamp the roof panel on all sides.
8. NOTICE: Electronic modules and related wiring may be damaged when exposed to heat from
welding procedures. Carefully disconnect and remove, or position away from heat affected
areas.
NOTE: Factory spot welds may be substituted with either resistance spot welds or Metal Inert Gas
(MIG) plug welds. Spot/plug welds should equal factory welds in both location and quantity. Do not
place a new spot weld directly over an original weld location. Plug weld hole should equal 8 mm
(0.31 in) diameter.

Using a Squeeze-Type Resistance Spot Welding (STRW) welding machine, weld the roof panel to the
vehicle at the windshield, rear header and roof ditch areas. Spot welds should match factory welds in
both location and quantity. Do not place a new spot weld directly over an original weld location.
9. Prepare the repair area for refinish material application following the paint manufacturer's
recommendations.
10. Apply a quality primer-sealer following the paint manufacturer's recommendation for both
compatibility and application.
11. NOTE: Always use refinishing materials from a single paint manufacturer. Combining products from
more than one manufacturer may result in refinishing material incompatibility issues and potential
void of warranty for each product applied.
If required, follow up with a quality primer-surfacer following the paint manufacturer's

recommendations. Block sand to level using the recommended grit sandpaper.
12. Apply roof ditch sealer to the roof ditch joints. Apply seam sealer to the joints on the front and rear
headers.
13. Refinish the roof and repair area following paint manufacturer's recommendations.
14. Install the safety canopies. For additional information, refer to Section 501-20B .
16. Install the liftgate. For additional information, refer to Section 501-03 .
17. Install the windshield and quarter glass. For additional information, refer to Section 501-11 .
After curing, test for air and water leaks.
18. Install the luggage rack (if equipped).

SECTION 502-02: Full Frame and Body Mounting 2011 Expedition, Navigator Workshop Manual
Description Nmlb-ft lb-in

Battery cable nut 9 - 80
Body mount bolts-to-frame 55 41 -
Camshaft Position (CMP) sensor bolts 10 - 89
Condenser-to-manifold and tube assembly nut 25 18 -
Frame-mounted heat shield bolts 20 - 177
Front End Sheet Metal (FESM) body mount bolts 80 59 -
Front skid plate bolts 40 30 -
Ground wire nut 12 - 106
No. 1 body mount bolt 103 76 -
No. 2 and 3 body mount bolts 80 59 -
No. 4 body mount nut 55 41 -
15 -133
Rear storage compartment body mount nuts 80 59 -
Spare tire winch bolts 20 - 177
Spare tire heat shield bolts 25 18 -
Steering shaft bolt 48 35 -
Tow hook bolts 80 59 -
Trailer hitch lower mounting bolts 275203 -
Trailer hitch side mounting bolts 175129 -
Transfer case skid plate bolts 25 18 -
Transmission mount nuts 103 76 -
Transmission crossmember bolts 66 -
Upper control arm heat shield 15 - 133


Frame and Body Mounting
The frame is made up of 2 steel boxed side rails and crossmembers, which are welded to the 2 side rails. The
transmission crossmember is bolted to the side rails. The side welded rails and crossmembers are not replaced
separately.
The service kits available for the frame are the following:
RH front horn replacement kit

LH front horn replacement kit
Front bumper bracket replacement kit
1B crossmember replacement kit
Transmission crossmember replacement kit
Exhaust hanger bracket kit
Refer to the instructions included in the kits for installation instructions. For any frame repair, refer to Section
501-35 .
Frame Mounted Heat Shields
All frame-mounted heat shields, except the spare tire heat shield and the upper control arm heat shield, are
tightened to 20 Nm (177 lb-in). The spare tire heat shield is tightened to 25 Nm (18 lb-ft). The upper control
arm heat shield is tightened to 15 Nm (133 lb-in).
Frame Components

1 - Body-to-frame mounts
2 - Front crossmember No. 1
3 - 1B crossmember
4 - RH frame rail
5 - Transmission crossmember
6 - Crossmember No. 3
Frame and Body Mounting 1142

10 - LH frame rail
11 - Tow hook bolt (4 required)
12 - Tow hook (2 required)
13 - Tow hook nut plate (2 required)
Spare Tire Winch

1 W505263 Spare tire winch bolt (3 required)
2 - Spare tire winch rivet (2 required)
3 W705589 Spare tire winch pushpin retainer (2
required)
4 - Spare tire winch cable guide
5 1A131 Spare tire winch assembly
6 eat shield bolt (3
required)
7 1A484 Spare tire heat shield
Skid Plates
Frame Components 1143


1 W503942 Front skid plate bolt (4 required)
2 5D032 Front skid plate
3 - Transfer case skid plate bolt (4 required)
4 7E063 Transfer case skid plate
NOTICE: When removing upper body mounts, enough adjacent body mount support bolts or nuts must
be removed to prevent damage occurring to the vehicle.
NOTE: Do not reuse body support mounting fasteners. New fasteners must be installed for each fastener that
has been removed or loosened.
NOTE: No lubricants of any kind are to be used during body mount installation.
Body Support - Front End Sheet Metal (FESM)

78001B39 Front End Sheet Metal (FESM)
mount bolt
2 7800193 Lower front end sheet metal
mount
3 7800192 Upper front end sheet metal
body mount
Skid Plates 1144

Body Support - No. 1

1 78001B39 Body mount bolt
2 7800192 Body support mount
3 W506433 Body mount bolt (2 required)
Body Support - No. 2 and No. 3
NOTE: No. 2 body mount shown, No. 3 body mount similar.

1 78001B39 Body support mount bolt
2 7800193 Lower body support mount
3 7800192 Upper body support mount
Body Support - No. 1 1145

Body Support - No. 4

1 W709518 Body mount nut and washer
2 W506433 Body mount bolt (2 required)
3 7800192 Body mount
Body Support - No. 4 1146

Transmission Support Crossmember
Transmission Support Crossmember Exploded View
NOTE: Transmission not shown for clarity.

1 W520114 Transmission support crossmember nut (4 required)
2 W705049 Transmission support crossmember bolt (4 required)
3 N621945 Transmission mount nut (2 required)
4 5059 Transmission support crossmember
100-02 .
2. If equipped, remove the skid plate fasteners and skid plate.
3. Remove the LH and RH exhaust heat shield-to-crossmember fasteners.
4. Remove the 2 transmission mount nuts.

Transmission Support Crossmember 1147

5. Support the transmission.
6. NOTE: Mark the transmission crossmember next to the edge of the frame bracket to make sure the
crossmember is installed in the same position it was removed from.
NOTE: The crossmember nuts are installed on the crossmember bolts facing the front of the vehicle.
Remove the 4 transmission crossmember bolts (2 each side) and the transmission crossmember.
Transmission Support Crossmember Exploded View 1148

Trailer Hitch

1 W708795 Trailer hitch side mounting bolt (4 required)
2 W711408 Trailer hitch lower mounting bolt (4 required)
3 17775 Trailer hitch
4 N611038 Trailer hitch lighting plug bolt (4 required)
5 14489 Trailer hitch lighting socket
6 - Trailer hitch electrical connector
7 - Trailer hitch wiring harness
WARNING: Do not permanently remove the trailer hitch. The trailer hitch is an integral part of the
vehicle frame. Always reinstall the hitch before delivery of the vehicle to the customer. Failure to follow
this instruction may compromise vehicle crash integrity and increase the risk of personal injury in a
rear end collision.
100-02 .
2. Remove the trailer hitch rear bumper cover trim panel, if equipped.
3. Remove the 4 trailer lighting plug cover bolts.
Trailer Hitch 1149

4. Remove the trailer lighting plug.

Position the plug away from the trailer hitch.
Disconnect the electrical conor.
Remove the trailer lighting plug.
5. Remove the electrical connector from the trailer hitch and unclip the harness from the retainers on the
frame.
6. Remove the 4 trailer hitch side mounting bolts (2 each side).

7. Remove the 4 trailer hitch lower mounting bolts (2 each side) and remove the trailer hitch.
Trailer Hitch 1150

Trailer Hitch 1151

Body
Special Tool(s)
Disconnect Tool, Transmission Cooler

Lines
307-459
Body Off Mounting Locations
Part
1 - Front End Sheet Metal (FESM) mounting bolts (2
required)
2 - Body mount No. 1 mounting bolts (2 required)
5 - Body mount No. 4 mounting bolt (2 required)
1. NOTE: A 2-post hoist must be used to lift the body from the chassis.
Open the tailgate.
100-02 .
Body 1152
3. Disconnect the battery cables. For additional information, refer to Section 414-01 .
4. Remove the nut and separate the leads from the battery positive cable and position aside.
5. Remove the nut and the ground wire from the right fender.
6. Remove the ground wire from the clip on the battery tray.
7. Recover the refrigerant. For additional information, refer to Section 412-00 .
8. Drain the engine coolant. For additional information, refer to Section 303-03 .
10. Remove the rear bumper cover. For additional information, refer to Section 501-19 .
11. Raise the vehicle.
12. Remove the running boards, if equipped. For additional information, refer to Section 501-08 .
13. Release the parking brake tension and disconnect the parking brake cable at the intermediate
connection.
14. Remove the parking brake cable-to-frame bolt.

Body Off Mounting Locations 1153

15. Disconnect the automatic transmission cable from the manual valve and retainer clip.
16. Disconnect the steering gear electrical connector and remove the connector from the frame.
17. Remove the retaining ring and disconnect the lower radiator hose from the radiator.
18. Remove the 4 pushpins (2 each side) from the frame-to-radiator air deflector.
19. Remove the safety clips from the transmission cooler lines.

20. Using the Transmission Cooler Lines Disconnect Tool, disconnect the transmission cooler lines from
the auxiliary cooler.
21. Remove the retainer from the splash shield on the front LH frame.
22. Remove the retainer from the splash shield on the front RH frame.
23. Remove the 3 retainers from the splash shield on the lower condenser.
24. Rotate the fan shroud upward to open it.
25. If equipped, disconnect the air hose from the air suspension compressor.

26. Remove the bolt and the ground wire from the body.
NOTE: Right front body bolt shown, all other bolts similar.
27. NOTE: Front End Sheet Metal (FESM) body support bolt shown, all other bolts similar.
Remove the 6 body mount bolts and 2 front end sheet metal body support bolts.
Discard the body bolts.

To install, tighten the FESM body mount No. 2 and No. 3 to 80 Nm (59 lb-ft).
To install, tighten No. 1 body mount to 103 Nm (76 lb-ft).
28. Lower the vehicle and chock the wheels to prevent the chassis from moving.
29. Remove the 2 bolt covers from the rear storage compartment.
30. Remove the 2 rear body mount nuts from the rear storage compartment.
Discard the nuts.

31. NOTICE: The fuel tank filler pipe may become caught on the inside of the fender when lifting
the vehicle. Make sure the fuel tank filler pipe is not binding when lifting the vehicle, or damage
may occur.
Remove the 3 screws from the fuel tank filler pipe.
32. Remove the engine cover, if equipped.
33. Remove the air cleaner intake pipe. For additional information, refer to Section 303-12 .
34. Disconnect the fuel bundle wiring harness connector and remove from the splash shield.
35. Disconnect the left ABS wheel speed sensor connector.
36. Disconnect the master cylinder electrical connector.
37. Disconnect the brake booster electrical connector.

38. Disconnect the canister purge valve electrical connector and remove it from the bracket, position the
canister aside.
39. Disconnect the electrical connector and the 2 hoses from the degas bottle/air cleaner module.
Unclip the RH hose from the retainers on the side of the degas bottle/air cleaner module.
40. Remove the 2 bolts from the degas bottle/air cleaner module and remove the module.
41. Remove the 2 master cylinder nuts (1 each side) from the brake booster and secure the master
cylinder to the engine.
42. Disconnect the brake booster vacuum supply hose and secure the hose to the engine.

43. NOTE: Make sure that the vehicle wheels are straight.
Place the vehicle in PARK and remove the key.
44. NOTICE: Do not allow the steering column shaft to rotate while the intermediate shaft is
disconnected or damage to the clockspring may result. If there is evidence that the shaft has
rotated, the clockspring must be removed and recentered. For additional information, refer to
Section 501-20B .
Remove the steering shaft bolt at the joint between the intermediate and lower shafts and separate the
shafts.
To install, refer to 48 Nm (35 lb-ft).
45. Disconnect the power steering reservoir-to-power steering pump hose.
46. Disconnect the power steering pump-to-power steering cooler line quick connect.
Disconnect the hose from the retainer on the fan shroud.
47. Disconnect the ABS module connector.

48. Disconnect the upper radiator hose from the engine.
49. Remove the nut from the condenser-to-manifold and tube assembly and position aside.
Install new O-rings before installing the manifold and tube assembly.
50. Remove the nut from the accumulator-to-manifold and tube assembly and position aside.
Install new O-rings before installing the manifold and tube assembly.
51. Remove the nut and disconnect the electrical connector from the generator wiring harness and remove
from the retainer.
52. Disconnect the electrical connector from the electrical thermal connector on the front of the engine.

53. NOTE: RH shown, LH similar.
Remove the bolts and the Camshaft Position (CMP) sensors (1 each side). Discard the O-ring seals.

Lubricate the O-ring seal with clean engine oil prior to installation.
54. If equipped, disconnect the right vacuum lines for the Four-Wheel Drive (4WD) hub actuators.
55. Disconnect the heater hose from the engine.
56. Disconnect the 3 heater hose quick disconnect fittings.
57. Disconnect the engine electrical connector from the PCM and remove the retainer from the bulkhead.

58. Disconnect the engine electrical connector from the wiring harness and position aside.
59. Disconnect the transmission electrical connector from the harness and the clip on the A/C line.
60. Disconnect the right side ABS wheel speed sensor connector.
61. Remove the bolt and the ground wire from the front of the bulkhead.
62. NOTE: Marking the position of the tires will aid in aligning the cab to the chassis.
Mark the position of the tires on the floor.
63. NOTE: A 2-post hoist must be used to lift the body from the chassis.
Position the hoist lift pads, equally side-to-side, below the pinch welds at the furthest most possible
front and rear positions.

64. WARNING: Securely strap the cab to the lift using an appropriate tool. If the cab is not
correctly secured, it could shift or fall. Failure to follow this instruction may result in serious
personal injury.
NOTICE: An assistant will be necessary to make sure all the connections are disconnected and
nothing interferes with the raising of the body while it is lifted.
With the aid of an assistant lift the body from the chassis.

Align the tires to the marks on the floor.
Top off the fluids.

SECTION 303-00: Engine System General 2011 Expedition, Navigator Workshop

Information Manual
Material

Capacity
Dye-Lite Gasoline Engine Oil
Leak Detection Dye
164-R3700 (Rotunda)
High Temperature Retaining WSK-M2G349-A9
Compound
Loctite 620 /Permatex
62050, or equivalent; obtain
locally
Motorcraft Metal Surface
Prep
ZC-31-A
Motorcraft SAE 5W-20 WSS-M2C945-A
Premium Synthetic Blend Motor
Oil (US); Motorcraft SAE
5W-20 Super Premium Motor
Oil (Canada)
XO-5W20-QSP (US);
CXO-5W20-LSP12 (Canada)
TA-26
Variable Camshaft Timing (VCT) oil control solenoid screw 5 44



SECTION 303-00: Engine System - General Information
Manual
Engine
NOTICE: When repairing engines, all parts must be contamination free. If contamination/foreign
material is present when repairing an engine, premature engine failure may occur.
NOTE: Specifications show the expected minimum or maximum condition. Refer to the appropriate section
in Group 303 for the procedure.
NOTE: If a component fails to meet the specifications, it is necessary to refinish it or install a new
component. Wear limits are provided as an aid to determine if the component can be refinished. A new
component must be installed when any component fails to meet specifications and cannot be refinished.
TE: This section contains information, steps and procedures that may not be specific to this engine.
This section covers general procedures and diagnosis and testing of the engine system, except for exhaust
emission control devices, which are covered in the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
The engine incorporates the following features: Refer to the appropriate section in Group 303 for the
procedure.
Crankcase ventilation or breather system

Exhaust emission control system
Evaporative Emission (EVAP) control system
Some engines incorporate a fail-safe cooling system. Refer to the appropriate section in Group 303 for the
procedure.
The engine, fuel system, ignition system, emissions system and exhaust system all affect exhaust emission
levels and must be maintained according to the maintenance schedule. Refer to the scheduled Maintenance
Guide.
Correct engine identification is required to order parts. Refer to the appropriate section in Group 303 for the
procedure.
For complete vehicle and engine identification codes, refer to Section 100-01 .
Engine 1166
Engine 1167

Manual
Engine
Special Tool(s)
12 Volt Master UV Diagnostic Inspection

Kit
164-R0756 or equivalent (Leak Detector)
Dial Indicator Gauge with Holding Fixture
100-002 (TOOL-4201-C) or equivalent
EngineEAR
EngineEAR/ChassisEAR
Oil Pressure Gauge

303-088 (T73L-6600-A)
Vacuum/Pressure Tester

Material
Item Specification
Dye-Lite Gasoline Engine Oil -
Leak Detection Dye
164-R3700 (Rotunda)
Motorcraft SAE 5W-20 Premium WSS-M2C945-A
Synthetic Blend Motor Oil (US);
Motorcraft SAE 5W-20 Super
Premium Motor Oil (Canada)
XO-5W20-QSP (US);
There are 2 diagnostic paths that can be followed depending on the type of engine concern. Carry out either
Inspection and Verification - Engine Performance or Inspection and Verification - Engine NVH.
Inspection and Verification - Engine Performance
Engine 1168
1. Verify the customer concern by operating the engine to duplicate the condition.
2. Visually inspect for obvious signs of mechanical damage. Refer to the following chart.
Mechanical
Engine coolant leaks
Engine oil leaks
Fuel leaks
Damaged or severely worn
parts
Loose mounting bolts, studs
and nuts
3. If the inspection reveals obvious concerns that can be readily identified, repair as necessary.
4. NOTE: Make sure to use the latest sctware release.



418-00 .
(CMDTCs).
8. Clear the continuous DTCs and carry out the self-test diagnostics for the PCM.
9. If the DTCs retrieved are related to the concern, refer to Section 419-10 and the Powertrain
Control/Emissions Diagnosis (PC/ED) manual.
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart - Engine Performance .
Inspection and Verification - Engine NVH
Engine 1169
1. Engine NVH symptoms should be identified using the diagnostic tools and techniques that are
available. For a list of these techniques, tools, an explanation of their uses and a glossary of common
terms, refer to Section 100-04 .
2. Verify the customer concern by operating the engine to duplicate the condition.
3. Inspect the engine for installation of an aftermarket oil filter. Review oil and filter maintenance
history to make sure that the vehicle has not gone beyond the standard Ford recommended oil change
interval.
4. Check the engine oil level and check the oil for contamination. Low engine oil level or contaminated
oil are common causes of engine noise. If the oil is contaminated the source of the contamination
must be identified and repaired as necessary.
Mechanical
Loose mounting bolts, studs and nuts
Damaged or leaking powertrain mounts
Damaged or disconnected vacuum hoses
Damaged or disconnected air intake components
Obstruction of cooling fan
Obstruction of Front End Accessory Drive (FEAD)
Obstruction of Rear End Accessory Drive (READ), if
equipped
l start="6">
If the inspection reveals obvious concerns that can be readily identified, repair as necessary.
If the cause is not visually evident, connect the scan tool to the DLC .
8. NOTE: The VCM LED prove out confirms power and ground from the DLC are provided to the
VCM .



418-00 .
Engine 1170
(CMDTCs).
12. If the DTCs retrieved are related to the concern, refer to Section 419-10 .
13. If no DTCs related to the concern are retrieved, continue the inspection and verification if a noise
concern is related to the engine. For vibration concerns and noise concerns such as powertrain
mounts, air intake system and starter, GO to Symptom Chart - Engine NVH .
In some cases, a noise may be a normal characteristic of that engine type. In other cases, the noise may require
further investigation. Comparing the noise to a similar year/model vehicle equipped with the same engine will
aid in determining if the noise is normal or abnormal.
Once a customer concern has been identified as an abnormal engine noise, it is critical to determine the
location of the specific noise. Use the EngineEAR/ChassisEAR or stethoscope (the noise will always be
louder the closer you get to the noise source) to isolate the location of the noise to one of the following areas.
Upper end of engine

Lower end of engine
Front of engine
Rear of engine
Upper end engine noise
Common sources of upper end engine noise (ticking, knocking or rattle) include the fuel injectors, camshaft
phaser sprocket(s), camshaft(s) and valve train. Upper end engine noise can be determined using the
EngineEAR/ChassisEAR or stethoscope on the valve cover bolts. If the noise is loudest from the valve cover
bolts, then the noise is upper end. The EngineEAR/ChassisEAR or stethoscope can be used to further isolate
the noise to the specific cylinder bank and cylinder. Removal of the valve covers will be required to pinpoint
the source of the noise.
Fuel Injector Noise

A common source of an engine ticking noise can be related to the fuel injector(s). This is
normal engine noise that can be verified by listening to another vehicle. If the injector noise is
excessive or irregular, use the EngineEAR/ChassisEAR or stethoscope to isolate the noise to
a specific fuel injector.
Camshaft Phaser and Sprocket Noise [Variable Camshaft Timing (VCT) Engines Only]
The camshaft phaser and sprocket may emit a light knock in normal operation and is audible
only at idle speed, with a hot engine (gear selector in park/neutral). If the camshaft phaser and
sprocket noise is excessive or irregular, use the EngineEAR/ChassisEAR or stethoscope to
isolate the noise to the LH or RH cylinder head. This normal noise is not prevalent at cold
temperature, the engine may require a cold soak overnight for a full diagnosis to effectively
be made at hot idle.
Valve Train
Lash adjusters can make an engine ticking or tapping noise noticeable at any engine rpm or
temperature and is audible through the wheel well or an open hood. However, with the hood
down, lash adjuster noise can be heard as a light tapping noise through the wheel well and is
considered normal. The EngineEAR/ChassisEAR or stethoscope can be used to further isolate
the noise to the specific cylinder bank and cylinder, some disassembly of the engine may be
required to inspect for damage or wear.
Upper end engine noise 1171

Lower end engine noise
A common source of lower end engine noise (ticking or knocking) include the crankshaft, connecting rod(s)
and bearings. Lower end noises can be determined by using the oil pan or cylinder block lug bosses. If the
noise is loudest from these areas then the noise is lower end. If an engine noise is isolated to the lower end,
some disassembly of the engine may be required to inspect for damage or wear.
Front of engine noise
A common source of noise from the front of the engine (squeal, chirp, whine or hoot) is the Front End
Accessory Drive (FEAD) components. To isolate FEAD noise, carry out the Engine Accessory Test, refer to
Section 100-04 .
Some other noises from the front of the engine (ticking, tapping or rattle) may be internal to the engine. Use
the EngineEAR/ChassisEAR or stethoscope on the engine front cover to determine if the noise is internal to
the engine. Removal of the engine front cover may be necessary to inspect internal engine components.
Rear of engine noise
A common source of noise from the rear of the engine (knocking) is the flywheel/flexplate. Inspection of the
flywheel/flexplate will be necessary.
14. After localizing the noise, note the characteristics of the noise, including type of noise, frequency and
conditions when the noise occurs and GO to Symptom Chart - Engine NVH .
Symptom Chart - Engine Performance
Symptom Chart - Engine Performance
Symptom Chart - Engine NVH
Symptom Chart - Engine NVH

NOTE: Engine NVH symptoms should be identified using the diagnostic tools that are available. For a list of
these tools, an explanation of their uses and a glossary of common terms, refer to Section 100-04 . Since it is
possible that any one of multiple systems may be the cause of the symptom, it may be necessary to use a
process of elimination type of diagnostic approach to pinpoint the responsible system. If this is not the causal
system for the symptom, refer back to Section 100-04 for the next likely system and continue diagnosis.
Drone type noise
Powertrain mount(s)
CARRY OUT the Powertrain/Drivetrain Mount Neutralizing procedure in this section.
Drumming noise - occurs inside the vehicle during idle or high idle, hot or cold. Very low-frequency
drumming is very rpm dependent
Engine vibration excites the body resonances inducing interior noise
Lower end engine noise 1172

Engine drumming noise - accompanied by vibration
Powertrain mount(s)
Rattle - occurs at idle or at light acceleration from a stop
Powertrain mount(s)
CHECK the powertrain mounts for damage. INSTALL new mounts as necessary. For engine, Refer to
the appropriate section in Group 303 for the procedure. For automatic transmission, Refer to the
appropriate section in Group 307 for the procedure/li>
Whine/moan type noise - pitch increases or changes with vehicle speed
Powertrain mount(s)
appropriate section in Group 307 for the procedure.
Clunk - occurs when shifting from PARK or between REVERSE and DRIVE
Powertrain mounts
CHECK the powertrain/drivetrain mounts for damage. INSTALL new mounts as necessary. For
engine, Refer to the appropriate section in Group 303 for the procedure. For automatic transmission,
Refer to the appropriate section in Group 307 for the procedure.
Idle speed is too high
CHECK for the correct idle speed. REFER to Powertrain Control/Emissions Diagnosis (PC/ED)
manual.
Accessory drive bearing hoot - occurs at idle or high idle in cold temperatures of approximately +4C
(+40F) or colder at the first start of the day
Accessory drive idler or tensioner pulley bearing is experiencing stick/slip between ball bearings and
the bearing race
CARRY OUT the engine cold soak procedure. REFER to Section 100-04 .
PLACE the EngineEAR probe directly on the idler/tensioner center post or bolt to verify which
bearing is making the noise. INSTALL new parts as necessary. REFER to Section 303-05 .
Accessory drive belt noise, squeal or chirping
Defee/worn or incorrect accessory drive belt

Misaligned pulley(s)
Pulley runout
Damaged or worn accessory drive component or idler
Fluid contamination of the accessory drive belt or pulleys
Rear of engine noise 1173

Damaged or worn accessory drive belt tensioner

Damaged pulley grooves
CARRY OUT the Engine Accessory Test. REFER to Section 100-04 . INSPECT components and
INSTALL new parts as necessary. REFER to Section 303-05 .
Clunking noise
Coolant pump has excessive end play or imbalance
CHECK the coolant pump for excessive end play. INSPECT the coolant pump for imbalance with the
drive belt off. INSTALL a new coolant pump as necessary. REFER to Section 303-03 .
Whine or moaning noise
Air intake system
CHECK the Air Cleaner (ACL) and ducts for correct fit. INSPECT the air intake system for leaks or
damage. REPAIR as necessary. REFER to Section 303-12 .
Whistling noise - normally accompanied with poor idle condition
Air intake system
CHECK the air intake ducts, ACL , Throttle Body (TB) and vacuum hoses for leaks and correct fit.
REPAIR or ADJUST as necessary. Refer to the appropriate section in Group 303 for the procedure.
Hissing noise - occurs during idle or high idle that is apparent with the hood open
Vacuum leak noise
USE the EngineEAR to locate the source. SCAN the air intake system from the inlet to each cylinder
intake port. DISCARD the leaking parts, and INSTALL a new component.
Vehicles with a plastic intake manifold
Accble condition. Some plastic manifolds exhibit this noise, which is the effect of the plastic
manifold.
Grinding noise - occurs during engine cranking
Incorrect starter motor mounting
INSPECT the starter motor for correct mounting. REPAIR as necessary. Refer to the appropriate
section in Group 303 for the procedure.
Starter motor
CHECK the starter motor. INSTALL a new starter motor as necessary. Refer to the appropriate
Incorrect starter motor drive engagement
INSPECT the starter motor drive for wear or damage. INSTALL a new starter motor as necessary.

INSPECT the flywheel/flexplate for wear or damage. INSTALL a new flywheel/flexplate as
necessary. Refer to the appropriate section in Group 303 for the procedure.
Engine noise, front of engine - knocking noise from lower front of engine
Damaged or separated crankshaft pulley/damper
CHECK for obvious signs of damage or wobble during operation. INSTALL new as necessary. Refer
to the appropriate section in Group 303 for the procedure.
Engine noise, front of engine - ticking, tapping or rattling noise from the front of the engine
Timing drive components
REMOVE the accessory drive belt. Refer to the appropriate section in Group 303 for the procedure.
USE the EngineEAR to isolthe noise to the engine front cover.
REMOVE the engine front cover and INSPECT the timing drive components. INSTALL new parts as
Engine noise, upper end - ticking noise near the fuel rail and intake manifold
Fuel rail clip
CHECK for loose or damaged fuel rail clip(s). REPAIR as necessary.
Fuel injector
USE the EngineEAR to isolate the noisy injector(s). INSTALL new injector(s) as necessary. Refer to
the appropriate section in Group 303 for the procedure.
Engine noise, upper end - ticking, knocking or rattle noise that occurs during idle or high idle during
the first cold start of the day and may disappear as the engine warms
Valve train noise (bled down lifter/lash adjuster)
CARRY OUT the Valve Train Analysis Component Test in this section. INSTALL new parts as
Engine noise, upper end - occurs mostly with a warm engine at light/medium acceleration
Worn or damaged spark plugs
REMOVE the spark plugs. INSPECT and INSTALL new as necessary. Refer to the appropriate
Carbon accumulation in combustion chamber
INSPECT the cylinder using a Bore scope. ELIMINATE carbon buildup.
Engine noise, upper end - rattling noise from the valve train. Worse when the engine is cold
Low oil level

CHECK the oil level. FILL as necessary.
Worn valve train components
CARRY OUT the Valve Train Analysis Component Test in this section. INSTALL new parts as
Worn valve guides
CARRY OUT the Valve Guide Inner Diameter procedure in this section.
Excessive runout of the valve seats on the valve face
CARRY OUT the Valve Seat Inspection procedure in this section.
Engine noise, upper end - pinging noise
Gasoline octane too low
VERIFY with customer the type of gasoline used. CORRECT as necessary.
Knock Sensor (KS) operation
CHECK the KS . INSTALL a new KS as necessary. Refer to the appropriate section in Group 303 for
the procedure.
Incorrect spark timing
REFER to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
High operating temperature
INSPECT the cooling system for leaks. CHECK the coolant level. REFILL as necessary. CHECK the
coolant for the correct mix ratio. DRAIN and REFILL as needed. VERIFY the engine operating
temperature is within specifications. REPAIR as necessary. Refer to the appropriate section in Group
303 for the procedure.
Spark plug
CHECK the spark plugs. REPAIR or INSTALL new spark plugs as necessary. Refer to the
Catalytic converter
Acceptable noise.
Engine noise, upper end - knocking or ticking noise, occurs mostly with a warm engine at idle
Low oil level
CHECK the oil level. FILL as necessary.
Thin or diluted oil

INSPECT the oil for contamination. If the oil is contaminated, CHECK for the source. REPAIR as
necessary. CHANGE the oil and filter.
Damaged or incorrect oil filter
INSPECT the oil filter. INSTALL a new oil filter as necessary.
Low oil pressure
CARRY OUT the oil pressure test.
Camshaft phaser and sprocket(s) [ VCT engines only]
Engine noise, lower end - ticking or knocking noise near the oil filter adapter
Oil pump
USE the EngineEAR to verify the oil pump as the source of the noise at low rpm. REPAIR as
Engine noise, lower end - light knocking noise, also described as piston slap. Noise is most noticeable
when the engine is cold with light to medium acceleration. The noise disappears as the engine warms
Excessive clearance between the piston and the cylinder wall
CARRY OUT the Piston To Cylinder Bore Clearance procedure in this section.
Engine noise, lower end - light double knock or sharp rap sound. Occurs mostly with a warm engine
at idle or low speeds in drive. Increases in relation to engine load. Associated with a poor lubrication
history
Excessive clearance between the piston and the piston pin
CARRY OUT the Piston Pin Bore Diameter procedure and the Piston Pin Diameter procedure in this
section.
Engine noise, lower end - light knocking noise. The noise is most noticeable when the engine is
warm. The noise tends to decrease when the vehicle is coasting or in NEUTRAL
Excessive clearance between the connecting rod bearings and the crankshaft
CARRY OUT the Connecting Rod Bearing Journal-to-Bearing Clearance procedure in this section.
Engine noise, lower end - deep knocking noise. The noise is most noticeable when the engine is
warm, at lower rpm and under a light load and then at float
Worn or damaged crankshaft main bearings
CARRY OUT the Crankshaft Main Bearing Journal-to-Bearing Clearance procedure in this section.
Engine noise, rear of engine - knocking noise at rear of engine

Damaged flywheel/flexplate
CARRY OUT the Flexplate Inspection procedure in this section.
Engine vibration - vibration felt at all times
Excessive crankshaft pulley runout
CARRY OUT the Engine Accessory Test. INSTALL a new crankshaft pulley as necessary. Refer to
the appropriate section in Group 303 for the procedure.
Damaged or worn accessory component
CARRY OUT the Engine Accessory Test. REPAIR or INSTALL a new component as necessary.
Engine vibration - at idle, a low-frequency vibration (5-20 Hz) or mild shake that is felt through the
seat/floorpan
Cylinder misfire
CARRY OUT the cylinder power balance and the relative compression test using the scan tool.
REPAIR as necessary. Refer to the appropriate section in Group 303 for the procedure.
Engine or torque converter out of balance
VERIFY the torque converter to crankshaft pilot clearance is correct. REPAIR as necessary.
RE-INDEX the torque converter on the flexplate by 120 degrees for a 3-bolt converter or 180 degrees
for a 4-bolt converter. Refer to the appropriate section in Group 307 for the procedure.
Engine vibration - is felt with increases and decreases in engine rpm
Powertrain mount(s)
Engine or transmission contacting the chassis
INSPECT the powertrain/drivetrain for correct clearances. REPAIR as necessary.
Engine vibration - increases intensity as the engine rpm is increased
Engine out-of-balance
CARRY OUT the Neutral Engine Run-Up (NERU) Test. REFER to Section 100-04 . ROTATE the
torque converter, 120 degrees for 3-bolt or 180 degrees for 4-bolt. INSPECT the torque converter
pilot outer diameter to crankshaft pilot inner diameter. REPAIR as necessary. Refer to the appropriate
Engine vibration - mostly at coast/neutral coast. Condition improves with vehicle acceleration
Combustion instability

CHECK the ignition system. INSTALL new components as neary. Refer to the appropriate section in
Group 303 for the procedure.
Engine vibration or shudder - occurs with light to medium acceleration above 56 km/h (35 mph)
Worn or damaged spark plugs
INSPECT the spark plugs for cracks, high resistance or broken insulators. INSTALL a new spark
plug(s) as necessary. Refer to the appropriate section in Group 303 for the procedure.
Plugged fuel injector
INSTALL a new fuel injector as necessary. Refer to the appropriate section in Group 303 for the
procedure.
Contaminated fuel
INSPECT the fuel for contamination. DRAIN the fuel system and refill.
Pinpoint Tests
Pinpoint Test A: Engine Noise, Upper End - Camshaft Phaser and Sprocket(s) [Variable Camshaft
Timing (VCT) Engines Only]

Camshaft phaser and sprocket noise
PINPOINT TEST A: ENGINE NOISE, UPPER END - CAMSHAFT PHASER AND SPROCKET(S) [ VCT ENGINES
ONLY]

A1 VERIFY THE CAMSHAFT
PHASER AND SPROCKET(S) NOISE
Yes
Ignition OFF. The concern is not VCT related. GO to Symptom Chart -
Disconnecting the RH and LH Engine NVH .
Variable Camshaft Timing (VCT)
solenoid electrical connectors. No
Start the vehicle and elevate the GO to A2 .
engine rpm and then return to idle.
Is the camshaft phaser and
sprocket noise still audible?
A2 CHECK THE ENGINE
MINIMUM OIL PRESSURE
Yes
Check the engine oil pressure. GO to A3 .
Carry out the oil pressure test.
No
PINPOINT TEST A: ENGINE NOISE, UPPER END - CAMSHAFT PHASER AND SPROCKET(S)
1179
[ VCT ENG
Is the oil pressure reading within GO to Pinpoint Test B .

the minimum specification?
A3 CHECK THE VCT HOUSING
OIL SCREEN FOR DEBRIS
Yes
Remove the VCT housing oil INSPECT the VCT camshaft phaser and sprockets and
screen and inspect for debris. REPAIR as necessary. REFER to Camshaft Phaser and
Is the VCT oil screen clean and Sprocket Inspection in this section.
free of debris?
No
REMOVE the VCT housing, Refer to the appropriate section
in Group 303 for the procedure. CLEAN and INSPECT the
VCT housing. REFER to Variable Camshaft Timing (VCT)
Housing Cleaning and Inspection in the section.
Pinpoint Test B: Low Oil Pressure
Normal Operation
Oil is drawn into the oil pump through the oil pump screen and pickup tube in the sump of the oil pan. Oil is
pumped through the oil filter on the left front side of the cylinder block then enters the main gallery where it is
distributed to the crankshaft main journals and to both cylinder heads. From the main journals, the oil is
routed through cross-drilled passages in the crankshaft to lubricate the connecting rod bearings. Controlled
leakage through the crankshaft main bearings and connecting rod bearings is slung radially outward to cool
and lubricate the cylinder walls as well as the entire connecting rod, piston and piston ring assembly. The left
cylinder head is fed from a drilling into the supply passage feeding the main gallery at the front of the cylinder
block. The right cylinder head is fed from a drilling into the rear of the main gallery. Main gallery pressure is
reduced as it enters the cylinder head galleries through fixed serviceable orifices, located at the upper part of
the feed passages. It is this reduced pressure in the cylinder head galleries which feed the camshaft journals,
the hydraulic lash adjusters and the primary and secondary timing chain tensioners. On Variable Camshaft
Timing (VCT) equipped engines, the oil pressure feed for the VCT solenoids, VCT housings and camshaft
phaser and sprockets is not reduced. The camshaft lobe and roller followers are lubricated by splash created
through valve train operation.

Excessive crankshaft end play
Excessive main bearing clearance
Excessive connecting rod bearing clearance
Excessive camshaft bearing cap clearance
Loose camshaft phaser and sprocket bolt(s) [ VCT engines only]
Loose oil galley plugs
Loose timing chain tensioner bolts
Loose VCT housing bolts [ VCT engines only]
Oil pump screen and pickup tube
Restricted oil flow passages
Worn or damaged oil pump
PINPOINT TEST B: LOW OIL PRESSURE

B1 CHECK THE CRANKSHAFT END PLAY

Check the crankshaft end play. Refer to Crankshaft End Yes

Play in this section. GO to B2 .
Is the crankshaft end play within specification?
No
REPAIR as necessary. Refer to the
appropriate section in Group 303 for
the procedure.
B2 VERIFY THE CAMSHAFT BEARING CAPS ARE NOT
DAMAGED AND TIGHT
Yes
Check that the camshaft bearing caps are not damaged and REPAIR as necessary. Refer to the
the bolts are properly tightened. Refer to the Specification appropriate section in Group 303 for
chart in the appropriate engine section. the procedure.
Are the camshaft bearing caps loose or damaged?
No
If the engine is equipped with VCT ,
GO to B3 ; for all other engines, GO
to B5 .
B3 VERIFY THE CAMSHAFT PHASER AND SPROCKET
BOLT(S) ARE TIGHT
Yes
Check that the camshaft phaser and sprocket bolt(s) are REPAIR as necessary. Refer to the
tight. Refer to the Specification chart in the appropriate appropriate section in Group 303 for
engine section. the procedure.
Are the camshaft phaser and sprocket bolt(s) loose?
No
GO to B4 .
B4 VERIFY THE VCT HOUSING BOLT(S) ARE TIGHT [
VCT ENGINES ONLY]
Yes
Check that the VCT housing bolts are tight. Refer to the REPAIR as necessary. Refer to the
Specification chart in the appropriate engine section. appropriate section in Group 303 for
Are the VCT housing bolts loose? the procedure.
No
GO to B5 .
B5 CHECK CAMSHAFT JOURNAL-TO-BEARING
CLEARANCE
Yes
Check the camshaft journal-to-bearing clearance. Refer to GO to B6 .
the Specification chart in the appropriate engine section.
Is camshaft journal-to-bearing clearance within No
specification? REPAIR as necessary. Refer to the
the procedure.
B6 CHECK FOR RESTRICTED OIL FLOW
Yes
Verify the oil supply and return passages are not plugged REPAIR as necessary. Refer to the
and clean of debris. Refer to the oil flow chart in the appropriate section in Group 303 for
appropriate engine section. the procedure.
Is oil flow restricted?
No
PINPOINT TEST B: LOW OIL PRESSURE 1181

GO to B7 .
B7 CHECK THE TIMING CHAIN TENSIONERS FOR
DAMAGE AND VERIFY THE BOLTS ARE TIGHT
Yes
Check that the timing chain tensioners are not damaged or REPAIR as necessary. Refer to the
the bolts are loose. Refer to the Specification chart in the appropriate section in Group 303 for
appropriate engine section. the procedure.
Are the timing chain tensioners damaged or bolts
loose? No
GO to B8 .
B8 CHECK THE OIL PUMP PICKUP TUBE AND SCREEN
FOR DAMAGE
Yes
Check that the oil pump pickup tube and screen is not REPAIR as necessary. Refer to the
plugged, cracked or that the bolts are loose. Refer to the appropriate section in Group 303 for
Specification chart in the appropriate engine section. the procedure.
Is the oil pump screen and pickup tube damaged or
loose? No
GO to B9 .
B9 CHECK THE OIL PUMP FOR DAMAGE
Yes
Verify the oil pump is not damaged. REPAIR as necessary. Refer to the
Is oil pump damaged? appropriate section in Group 303 for
the procedure.
No
GO to B10 .
B10 CHECK CRANKSHAFT MAIN BEARING
JOURNAL-TO-BEARING CLEARANCE
Yes
Check the crankshaft main bearing journal-to-bearing GO to B11 .
clearance. Refer to the Specification chart in the
appropriate engine section. No
Is crankshaft main bearing journal-to-bearing REPAIR as necessary. Refer to the
clearance within specification? appropriate section in Group 303 for
the procedure.
B11 CHECK CONNECTING ROD BEARING
JOURNAL-TO-BEARING CLEARANCE
Yes
Check the connecting rod bearing journal-to-bearing The concern may have been caused
clearance. Refer to the Specification chart in the by debris or an incorrect assembly.
appropriate engine section. REPEAT the oil pressure test.
Is connecting rod bearing journal-to-bearing clearance
within specification? No
REPAIR as necessary. Refer to the
the procedure.
Component Tests
The following component tests are used to diagnose engine concerns.

Engine Oil Leaks
NOTICE: If an overnight drive is done, the fan air or road air blast may cause erroneous readings.
NOTE: When diagnosing engine oil leaks, the source and location of the leak must be positively identified
prior to repair.
Prior to carrying out this procedure, clean the cylinder block, cylinder heads, valve covers, oil pan and
flywheel with a suitable solvent to remove all traces of oil.
Engine Oil Leaks - Fluorescent Oil Additive Method
Use the 12 Volt Master UV Diagnostic Inspection Kit to carry out the following procedure for oil leak
diagnosis.
1. Add 29.6 ml (1 oz) of gasoline engine oil dye to a minimum of 0.47L (1/2 qt) and a maximum of
0.95L (1 qt) engine oil and fill through the engine oil fill. If the oil is not prixed, the gasoline engine
oil dye will not have enough time to reach the crankcase, oil galleries and seal surfaces during this
particular 15 minute test. The gasoline engine oil dye must be mixed with oil and added through the
oil fill. Check the level on the oil level indicator to determine what amount of oil to premix. If it is in
the middle of the crosshatch area or below the full mark, use 0.95L (1 qt). If it is at the full mark, use
0.47L (1/2 qt).
2. Run the engine for 15 minutes. Stop the engine and inspect all seal and gasket areas for leaks using
the UV Diagnostic Inspection Kit. A clear bright yellow or orange area will identify the leak. For
extremely small leaks, several hours may be required for the leak to appear.
3. At the end of test, make sure the oil level is within the upper and lower oil indicator marks. Remove
oil as necessary if it registers above the full mark.
Leakage Points - Underhood
Examine the following areas for oil leakage:
Valve cover gaskets

Cylinder head gaskets
Oil cooler, if equipped
Oil filter adapter
Engine front cover
Oil filter adapter and filter body
Oil level indicator tube connection
Engine Oil Pressure (EOP) sensor
Leakage Points - Under Engine, With Vehicle on Hoist
Oil pan gaskets

Oil pan sealer
Engine front cover gasket
Crankshaft front seal
Crankshaft rear oil seal
Oil filter adapter and filter body

Oil cooler, if equipped
Leakage Points - With Transmission and Flywheel Removed
Crankshaft rear seal

Crankshaft rear seal retainer
Rear main bearing cap parting line
Flexplate mounting bolt holes (with ate installed)
Pipe plugs at the end of oil passages
Oil leaks at crimped seams in sheet metal parts and cracks in cast or stamped parts can be detected when using
the Gasoline Engine Oil Dye method.
Compression Test - Compression Gauge Check
1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the
battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature.
Turn the ignition switch to the OFF position, then remove all the spark plugs.
2. Set the throttle plates in the wide-open position.
3. Install a compression gauge in the No. 1 cylinder.
4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position,
and using the auxiliary starter switch, crank the engine a minimum of 5 compression strokes and
record the highest reading. Note the approximate number of compression strokes required to obtain
the highest reading.
5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression
strokes.
Compression Test - Test Results
The indicated compression pressures are considered within specification if the lowest reading cylinder is at
least 75% of the highest reading. Refer to the Compression Pressure Limit Chart.
Compression Pressure Limit Chart
Compression Pressure Limit Chart 1184

If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in
the lowding cylinders. Repeat the compression pressure check on these cylinders.
Compression Test - Interpreting Compression Readings
1. If compression improves considerably, piston rings are faulty.
2. If compression does not improve, valves are sticking or seating incorrectly.
3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not
increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in
cylinders could result from this condition.
Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest
reading is within 75% of the highest reading.
Cylinder Leakage Detection
When a cylinder produces a low reading, use of a cylinder leakage tester will be helpful in pinpointing the
exact cause.
The leakage tester is inserted in the spark plug hole, the piston is brought up to dead center on the
compression stroke and compressed air is admitted.
Once the combustion chamber is pressurized, the leakage tester gauge will read the percentage of leakage.
Leakage exceeding 20% is excessive.
While the air pressure is retained in the cylinder, listen for the hiss of escaping air. A leak at the intake valve
will be heard in the Throttle Body (TB). A leak at the exhaust valve can be heard at the tail pipe. Leakage past
the piston rings will be audible at the PCV connection. If air is passing through a blown head gasket to an
adjacent cylinder, the noise will be evident at the spark plug hole of the cylinder into which the air is leaking.
Cracks in the cylinder block or gasket leakage into the cooling system may be detected by a stream of bubbles
in the radiator.

Excessive Engine Oil Consumption
Nearly all engines consume oil, which is essential for noal lubrication of the cylinder bore walls and pistons
and rings. Determining the level of oil consumption may require testing by recording how much oil is being
added over a given set of miles.
Customer driving habits greatly influence oil consumption. Mileage accumulated during towing or heavy
loading generates extra heat. Frequent short trips, stop-and-go type traffic or extensive idling, prevent the
engine from reaching normal operating temperature. This prevents component clearances from reaching
specified operating ranges.
The following diagnostic procedure may be utilized to determine internal oil consumption. Make sure that the
concern is related to internal oil consumption, and not external leakage, which also consumes oil. Verify there
are no leaks before carrying out the test. Once verified, the rate of internal oil consumption can be tested.
A new engine may require extra oil in the early stages of operation. Internal piston-to-bore clearances and
sealing characteristics improve as the engine breaks in. Engines are designed for close tolerances and do not
require break-in oils or additives. Use the oil specified in the Owner's Literature. Ambient temperatures may
determine the oil viscosity specification. Verify that the correct oil is being used for the vehicle in the
geographic region in which it is driven.
Basic Pre-checks
1. For persistent complaints of oil consumption, interview the customer to determine the oil
consumption characteristics. If possible, determine the brand and grade of oil currently in the oil pan.
Look at the oil filter or oil-change station tags to determine if Ford-recommended maintenance
schedules have been followed. Make sure that the oil has been changed at the specified mileage
intervals. If vehicle mileage is past the first recommended drain interval, the OEM production filter
should have been changed.
2. Ask how the most current mileage was accumulated. That is, determine whether the vehicle was
driven under the following conditions:
Extended idling or curbside engine operation
Stop-and-go traffic or taxi operation
Towing a trailer or vehicle loaded heavily
Frequent short trips (engine not up to normal operating temperature)
Excessive throttling or high engine-rpm driving
3. Verify that there are no external leaks. If necessary, review the diagnostic procedure under Engine Oil
Leaks in the Diagnosis and Testing portion of this section.
4. Inspect the crankcase ventilation system for:

disconnected hoses at the valve cover or TB .
loose or missing valve cover fill cap.
missing or incorrectly seated engine oil level indicator.
incorrect or dirty PCV valve.
a PCV valve grommet unseated in the valve cover (if so equipped).
5. Inspect for signs of sludge. Sludge affects PCV performance and can plug or restrict cylinder head
drainback wells. It can also increase oil pressure by restricting passages and reducing the drainback
capability of piston oil control rings.
6. Inspect the air filter for dirt, sludge or damage. A hole in the filter element will allow unfiltered air to

bypass into the air induction system. This can cause premature internal wear (engine dusting),
allowing oil to escape past rings, pistons, valves and guides.
7. If the engine is hot or was recently shut down, wait at least 5 minutes to allow the oil to drain back.
Ask the customer if this requirement has been followed. Adding oil without this wait period can cause
an overfill condition, leading to excessive oil consumption and foaming which may cause engine
damage.
8. Make sure the oil level indicator (dipstick) is correctly and fully seated in the indicator tube. Remove
the oil level indicator and record the oil level.
Detailed Pre-checks
1. Check the thermostat opening temperature to make sure that the cooling system is operating at the
specified temperature. If it is low, internal engine parts are not running at specified internal operating
clearances.
2. Verify the spark plugs are not oil saturated. Oil leaking into one or more cylinders will appear as an
oil soaked condition on the plug. If a plug is saturated, a compression check may be necessary at the
conclusion of the oil consumption test.
Oil Consumption Test
Once all of the previous conditions are met, carry out an oil consumption test.
1. Drain the engine oil and remove the oil filter. Install a new manufacturer-specified oil filter. Make
sure the vehicle is positioned on a level surface. Refill the oil pan to a level one liter (quart) less than
the specified fill level, using manufacturer-specified oil.
2. Run the engine for 3 minutes (if hot) or 10 minutes (if cold). Allow for a minimum 5-minute
drainback period and then record the oil level shown on the oil level indicator. Place a mark on the
backside of the oil level indicator noting the oil level location.
3. Add the final 0.95L (1 qt) to complete the normal oil fill. Restart the engine and allow it to idle for 2
minutes. Shut the engine down.
4. After a 5-minute drainback period, record the location of the oil level again. Mark the oil level
indicator with the new oil level location. (Note: Both marks should be very close to the MIN-MAX
upper and lower limits or the upper and lower holes on the oil level indicator. These marks will
exactly measure the engine's use of oil, with a one quart differential between the new marks.)
Demonstrate to the customer that the factory-calibrated marks on the oil level indicator are where the
oil should fall after an oil change with the specified fill amount. Explain however, that this may vary
slightly between MIN-MAX or the upper and lower holes on the oil level indicator.
5. Record the vehicle mileage.
6. Advise the customer that oil level indicator readings must be taken every 320 km (200 mi) or weekly,
using the revised marks as drawn. Remind the customer that the engine needs a minimum 5-minute
drainback for an accurate reading and that the oil level indicator must be firmly seated in the tube
prior to taking the reading.
7. When the subsequent indicator readings demonstrate a full quart (liter) has been used, record the
vehicle mileage. The mileage driven between the 2 readings should not be less than 4,800 km (3,000
miles). The drive cycle the vehicle has been operated under must be considered when making this

calculation. It may be necessary to have the customer bring the vehicle in for a periodic oil level
indicator reading to closely monitor oil usage.
Post Checks, Evaluation and Corrective Action
1. If test results indicate excessive oil consumption, carry out a cylinder compression test. The cylinder
compression test should be carried out with a fully charged battery and all spark plugs removed. See
the Compression Test Chart in this section for pressure range limits.
2. Compression should be consistent across all cylinders. Refer to the Compression Testing portion of
this section. If compression tested within the specifications found in this section, the excessive oil
consumption may be due to wear on the valve guides, valves or valve seals.
3. A cylinder leak detection test can be carried out using a cylinder leakage tester. This can help identify
valves, piston rings, or worn valve guides/valve stems, inoperative valve stem seals or other related
areas as the source of oil consumption.
NOTE: An oil-soaked appearance on the porcelain tips of the spark plugs also indicates excessive oil use. A
typical engine with normal oil consumption will exhibit a light tan to brown appearance. See Spark Plug
Analysis in this section for details. A single or adjoining, multiple cylinder leak can be traced by viewing the
tips.
4. If an internal engine part is isolated as the root cause, determine if the repair will exceed cost limits
and proceed with a repair strategy as required.
5. Once corrective action to engine is complete and verifying that all pre-check items were eliminated in
the original diagnosis, repeat the Oil Consumption Test as described above and verify consumption
results.
Intake Manifold Vacuum Test
Bring the engine to normal operating temperature. Connect the Vacuum/Pressure Tester to the intake
manifold. Run the engine at the specified idle speed.
The vacuum gauge should read between 51-74 kPa (15-22 in-Hg) depending upon the engine condition and
the altitude at which the test is performed. Subtract 4.0193 kPa (1 in-Hg) from the specified reading for every
304.8 m (1,000 ft) of elevation above sea level.
The reading should be steady. If necessary, adjust the gauge damper control (where used) if the needle is
fluttering rapidly. Adjust the damper until the needle moves easily without excessive flutter.
Intake Manifold Vacuum Test - Interpreting Vacuum Gauge Readings
A careful study of the vacuum gauge reading while the engine is idling will help pinpoint trouble areas.
Always conduct other appropriate tests before arriving at a final diagnostic decision. Vacuum gauge readings,
although helpful, st be interpreted carefully.
Most vacuum gauges have a normal band indicated on the gauge face.
The following are potential gauge readings. Some are normal; others should be investigated further.

1. NORMAL READING: Needle between 51-74 kPa (15-22 in-Hg) and holding steady.
2. NORMAL READING DURING RAPID ACCELERATION AND DECELERATION: When the

engine is rapidly accelerated (dotted needle), the needle will drop to a low reading (not to zero). When
the throttle is suddenly released, the needle will snap back up to a higher than normal figure.
3. NORMAL FOR HIGH-LIFT CAMSHAFT WITH LARGE OVERLAP: The needle will register as
low as 51 kPa (15 in-Hg), but will be relatively steady. Some oscillation is normal.
4. WORN RINGS OR DILUTED OIL: When the engine is accelerated (dotted needle), the needle drops
to 0 kPa (0 in-Hg). Upon deceleration, the needle runs slightly above 74 kPa (22 in-Hg).
5. STICKING VALVES: When the needle (dotted) remains steady at a normal vacuum, but occasionally
flicks (sharp, fast movement) down and back about 13 kPa (4 in-Hg), one or more valves may be
sticking.
6. BURNED OR WARPED VALVES: A regular, evenly-spaced, downscale flicking of the needle

indicates one or more burned or warped valves. Insufficient hydraulic lash adjuster or hydraulic lash
adjuster clearance will also cause this reaction.
7. POOR VALVE SEATING: A small but regular downscale flicking can mean one or more valves are
not seating.
8. WORN VALVE GUIDES: When the needle oscillates over about a 13 kPa (4 in-Hg) range at idle
speed, the valve guides could be worn. As engine speed increases, the needle will become steady if
guides are responsible.
9. WEAK VALVE SPRINGS: When the needle oscillation becomes more violent as engine rpm is
increased, weak valve springs are indicated. The reading at idle could be relatively steady.
10. LATE VALVE TIMING: A steady but low reading could be caused by late valve timing.
11. IGNITION TIMING RETARDING: Retarded ignition timing will produce a steady, but somewhat
low, reading.
12. INSUFFICIENT SPARK PLUG GAP: When spark plugs are gapped too close, a regular, small
pulsation of the needle can occur.
13. INTAKE LEAK: A low, steady reading can be caused by an intake manifold or throttle body gasket
leak.

14. BLOWN HEAD GASKET: A regular drop of fair magnitude can be caused by a blown head gasket
or warped cylinder head-to-cylinder block surface.
15. RESTRICTED EXHAUST SYSTEM: When the engine is first started and is idled, the reading may
be normal, but as the engine rpm is increased, the back pressure caused by a clogged muffler, kinked
tail pipe or other concerns will cause the needle to slowly drop to 0 kPa (0 in-Hg). The needle then
may slowly rise. Excessive exhaust clogging will cause the needle to drop to a low point even if the
engine is only idling.
16. When vacuum leaks are indicated, search out and correct the cause. Excess air leaking into the system
will upset the fuel mixture and cause concerns such as rough idle, missing on acceleration or burned
valves. If the leak exists in an accessory unit such as the power brake booster, the unit will not
function correctly. Always fix vacuum leaks.
Oil Pressure Test
NOTICE: Inspect the engine for installation of an aftermarket oil filter. Review oil and filter
maintenance history to make sure that the vehicle has not gone beyond the standard Ford
recommended oil change intervals. Check the engine oil level and check the oil for contamination. If the
oil is contaminated, engine damage can occur, the source of the contamination must be identified and
repaired as necessary.
1. Disconnect and remove the Engine Oil Pressure (EOP) switch from the engine. Refer to the
2. Connect the Oil Pressure Gauge to the oil pressure port.
3. Run the engine until normal operating temperature is reached.
4. With the engine at idle record the gauge reading.
5. Run the engine at 2,000 rpm and record the gauge reading.
6. The oil pressure should be within specifications; refer to the specifications in the appropriate engine
section.
7. If the pressure is not within specification, GO to Pinpoint Test B .
Valve Train Analysis
The following component tests are used to diagnose valve train concerns.
Valve Train Analysis - Engine Off - Valve Cover Removed
Check for damaged or severelrn parts and correct assembly. Make sure correct parts are used with the static
engine analysis as follows.
Valve Train Analysis - Engine Off, Camshaft Roller Followers and Hydraulic Lash Adjusters,
Overhead Camshaft
Check for loose mounting bolts on camshaft carriers.

Check for plugged oil feed in the camshaft roller followers, lash adjusters or cylinder heads.

Valve Train Analysis - Engine Off, Camshaft - Engines
Check for broken or damaged parts.
Valve Train Analysis - Valve Springs
Check for broken or damaged parts.
Valve Train Analysis - Engine Off, Valve Spring Retainer and Valve Spring Retainer Keys
Check for correct seating of the valve spring retainer key on the valve stem and in valve spring
retainer.
Check for correct seating on the valve stem.
Valve Train Analysis - Engine Off, Valves and Cylinder Head
Check for plugged oil drain back holes.

Check for worn or damaged valve tips.
Check for missing or damaged guide-mounted valve stem seal.
Check for damaged hydraulic lash adjuster.
Check installed valve spring height.
Check for missing or worn valve spring seats.
Check for plugged oil metering orifice in cylinder head oil reservoir (if equipped).
Static checks (engine off) are to be made on the engine prior to the dynamic procedure.
Valve Train Analysis - Engine Running, Valves and Cylinder Head
Check for plugged oil drain back holes.

Check for missing or damaged valve stem seals or guide mounted valve stem seals.
Check for a plugged oil metering orifice in the cylinder head oil reservoir.
If insufficient oiling is suspected, check oil passages for blockage, then accelerate the engine to 1,200 rpm
with th in NEUTRAL and the engine at normal operating temperature. Oil should spurt from the rocker arm
oil holes such that valve tips and camshaft roller followers are well oiled. With the valve covers off, some oil
splash may overshoot camshaft roller followers.
Valve Train Analysis - Camshaft Lobe Lift
Check the lift of each camshaft lobe in consecutive order and make a note of the readings.
1. Remove the spark plugs.
2. Install the Dial Indicator Gauge with Holding Fixture so the rounded tip of indicator is on top of the
camshaft lobe.
3. Rotate the crankshaft using a breaker bar and socket attached to the crankshaft pulley retainer bolt.
Rotate the crankshaft until the base circle of the camshaft lobe is reached.

4. Zero the Dial Indicator Gauge. Continue to rotate the crankshaft until the (1) high-lift point of the
camshaft lobe is in the fully-raised position (highest indicator reading).
5. To check the accuracy of the original indicator reading, continue to rotate crankshaft until the (2) base
circle is reached. The indicator reading should be zero. If zero reading is not obtained, repeat the
measurement.
6. If the lift on any lobe is below specified service limits, install a new camshaft and camshaft roller
followers.
7. Install the spark plugs.


Manual
Sprockets
1. Inspect the sprockets for cracks and worn or chipped teeth.
Sprockets 1193

Manual
Variable Camshaft Timing (VCT) Housing Cleaning and Inspection
Material
Item Specification
ZC-31-A
1. Remove the screw and the Variable Camshaft Timing (VCT) oil control solenoid.
2. Clean the mating surfaces and oil passages with metal surface prep. Follow the directions on the
packaging.
Inspect the VCT housing for pitting, cracks or damaged sealing surfaces. Install a new VCT housing if
damaged.
Variable Camshaft Timing (VCT) Housing Cleaning and Inspection 1194

Variable Camshaft Timing (VCT) Housing Cleaning and Inspection 1195


Manual
Camshaft Phaser and Sprocket Inspection
1. Inspect the front of the camshaft phaser and sprocket for missing or damaged roll pins.
If the roll pins are missing or damaged, a new camshaft phaser and sprocket must be installed.
2. Inspect the rear of the camshaft phaser and sprocket for a deformed or damaged location pin.
If the location pin is deformed or damaged, a new camshaft phaser and sprocket must be
installed.
3. Visually inspect the camshaft phaser and sprocket for squareness (A). If the trigger wheel or spring is
deformed or damaged (B), install a new camshaft phaser and sprocket.
Camshaft Phaser and Sprocket Inspection 1196

Camshaft Phaser and Sprocket Inspection 1197


Manual
Camshaft Bearing Journal Diameter
NOTE: Refer to the appropriate Section 303-01 for the specification.
1. Measure each camshaft journal diameter in 2 directions.
Camshaft Bearing Journal Diameter 1198


Manual
Camshaft Journal to Bearing Clearance - OHC Engines
1. NOTE: The camshaft journals must meet specifications before checking camshaft journal clearance.
Measure each camshaft bearing in 2 directions.
Subtract the camshaft journal diameter from the camshaft bearing diameter.
Camshaft Journal to Bearing Clearance - OHC Engines 1199


Manual
Camshaft End Play - OHC Engines
Special Tool(s)

1. Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft end play.
3. Zero the Dial Indicator Gauge.
4. Move the camshaft to the front of the cylinder head. Note and record the camshaft end play.
If camshaft end play exceeds specifications, install a new camshaft and recheck end play.
If camshaft end play exceeds specification after camshaft installation, install a new cylinder
head.
Camshaft End Play - OHC Engines 1200


Manual
Camshaft Surface Inspection
1. Inspect camshaft lobes for pitting or damage in the contact area. Minor pitting is acceptable outside
the contact area.
Camshaft Surface Inspection 1201


Manual
Camshaft Lobe Lift
Special Tool(s)
Dial Indator Gauge with Holding Fixture

1. Use the Dial Indicator Gauge with Holding Fixture to measure camshaft intake/exhaust lobe lift.
Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest
Dial Indicator Gauge reading to figure the camshaft lobe lift.
Camshaft Lobe Lift 1202


Manual
Camshaft Runout
Special Tool(s)

1. NOTE: Camshaft journals must be within specifications before checking runout.
Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft runout.
Camshaft must be supported on the first and last camshaft bearing journal.
Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest
Dial Indicator Gauge reading.
Camshaft Runout 1203


Manual
Crankshaft Main Bearing Journal Diameter
1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions.
&nbs
Crankshaft Main Bearing Journal Diameter 1204


Manual
Crankshaft Main Bearing Journal Taper and Out-of-Round
1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions at each end of
the main bearing journal.
Crankshaft Main Bearing Journal Taper and Out-of-Round 1205


Manual
Crankshaft Main Bearing Journal-to-Bearing Clearance
NOTE: Crankshaft main bearing journals must be within specifications before checking journal clearance.
1. Remove the crankshaft main bearing caps and crankshaft main bearing.
2. Lay a piece of Plastigage across the face of each crankshaft main bearing surface.
3. <NOTE: Do not turn the crankshaft while carrying out this procedure.Install and remove the
crankshaft main bearing cap.
4. Verify the crankshaft journal clearance.
Crankshaft Main Bearing Journal-to-Bearing Clearance 1206


Manual
Crankshaft End Play
Special Tool(s)

NOTE: Rer to the appropriate Section 303-01 for the specification.
1. Install the Dial Indicator Gauge with Holding Fixture.
2. Position the crankshaft to the rear of the cylinder block.
4. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
Crankshaft End Play 1207


Manual
Cylinder Bore Taper
1. Measure the cylinder bore at the top, middle and bottom of piston ring travel in 2 directions as
indicated. Verify the cylinder bore is within the wear limit. The difference indicates the cylinder bore
taper. If the cylinder bore taper does not meet specification, bore the cylinder to the next oversize
limit.
Cylinder Bore Taper 1208


Manual
Cylinder Bore Out-of-Round
1. Measure the cylinder bore in 2 directions. The difference is the out-of-round.
>
Cylinder Bore Out-of-Round 1209


Manual
GENERAL PROCEDURES Procedure revision date: 08//2010
Piston Inspection
Special Tool(s)
Scraper, Piston Ring Groove

303-D033 (D81L-6002-D) or equivalent
NOTICE: Do not use a caustic cleaning solution or a wire brush to clean the pistons or damage can
occur.
1. Clean and inspect the (1) ring lands, (2) skirts, (3) pin bosses and the (4) tops of the pistons. If wear
marks, scores or glazing is found on the piston skirt, check for a bent or twisted connecting rod.
2. Use the Piston Ring Groove Scraper to clean the piston ring grooves.
Make sure the oil ring holes are clean.
Piston Inspection 1210

Piston Inspection 1211


Manual
Piston Pin Bore Diameter
1. NOTE: Piston and piston pins are a matched set and should not be interchanged.
Measure the piston pin bore diameter in 2 directions on each side. Verify the diameter is within
specification.
Piston Pin Bore Diameter 1212


Manual
Piston Diameter
1. Measure the piston diameter 90 degrees from the piston pin and 42 mm (1.65 in) down from the top of
the piston at the point indicated.
Piston Diameter 1213


Manual
Piston To Cylinder Bore Clearance
1. Subtract the piston diameter from the cylinder bore diameter to find the piston-to-cylinder bore
clearance.
Piston To Cylinder Bore Clearance 1214


Manual
Piston Selection
NOTE: The cylinder bore must be within the specifications for taper and out-of-round before fitting a piston.
1. Select a piston size based on the cylinder bore.
2. NOTE: For precision fit, new pistons are divided into 3 categories within each size range based on
their lative position within the range. A paint spot or specific size grade on a new piston indicates the
position within the size range.
Choose the piston with the correct paint color or specific size grade.
Piston Selection 1215


Manual
Piston Ring End Gap
Special Tool(s)
Feeler Gauge Set

303-D027 (D81L-4201-A) or equivalent
NOTICE: Use care when fitting piston rings to avoid possible damage to t piston ring or the cylinder
bore.
NOTE: Piston rings should not be transferred from one piston to another.
NOTE: The cylinder bore must be within specification for taper and out-of-round.
1. Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel.
2. Use the Feeler Gauge Set to measure the top piston ring end gap and the second piston ring end gap.
Piston Ring End Gap 1216

Piston Ring End Gap 1217


Manual
Piston Ring-to-Groove Clearance
Special Tool(s)
Feeler Gauge Set

NOTE: Refer to the appropriate Section 303-01 for t specification.
1. Inspect the piston for ring land damage or accelerated wear.
2. Using the Feeler Gauge Set, measure the piston ring-to-groove clearance.
Piston Ring-to-Groove Clearance 1218


Manual
Piston Pin Diameter
1. Measure the piston pin diameter in 2 directions at the points shown. Verify the diameter is within
specification.
>
Piston Pin Diameter 1219


Manual
Connecting Rod Cleaning
NOTICE: Do not use a caustic cleaning solution or damage to connecting rods can occur.
1. NOTE: The connecting rod large end is a matched set. The connecting rod cap must be installed on
the original connecting rod in the original position. Do not reverse the cap. Parts are not
interchangeable.
Mark and separate the parts and clean with solvent. Clean the oil passages.
Connecting Rod Cleaning 1220


Manual
Connecting Rod Large End Bore
1. Tighten the bolts to specification, then measure the bore in 2 directions. The difference is the
connecting rod bore out-of-round. Verify the out-of-round is within specification.
Connecting Rod Large End Bore 1221


Manual
Connecting Rod Bushing Diameter
1. Use a telescoping gauge to determine the ID of the connecting rod bushing, if equippe
2. Measure the telescoping gauge with a micrometer. Verify the diameter is within specification.
Connecting Rod Bushing Diameter 1222


Manual
Connecting Rod Bend
Special Tool(s)
Feeler Gauge Set

1. Using the Feeler Gauge Set, measure the connecting rod bend on a suitable alignment fixture. Follow
the instructions of the fixture manufacturer. Verify the bend measurement is within specification.
Connecting Rod Bend 1223


Manual
Connecting Rod Twist
Special Tool(s)
Feeler Gauge Set

Using the Feeler Gauge Set, measure the connecting rod twist on a suitable alignment fixture. Follow the
instructions of the fixture manufacturer. Verify the measurement is within specification.
Connecting Rod Twist 1224


Manual
Connecting Rod to Crankshaft Side Clearance
Special Tool(s)
Feeler Gauge Set

1. Using the Feeler Gauge Set, measure the clearance between the connecting rod and the crankshaft.
Verify the measurement is within specification.
Connecting Rod to Crankshaft Side Clearance 1225


Manual
Connecting Rod Bearing Journal-to-Bearing Clearance
NOTE: The crankshaft connecting rod journals must be within specifications to check the connecting rod
bearing journal clearance.
1. Remove the connecting rod bearing cap.
2. Position a piece of Plastigage across the bearing surface.
3. NOTE: Do not turn the crankshaft during this step.
Install and tighten to specifications, then remove the connecting rod bearing cap.
4. Measure the Plastigage to get the connecting rod bearing journal clearance. The Plastigage should be
smooth and flat. A changing width indicates a tapered or damaged connecting rod or connecting rod
bearing.
Connecting Rod Bearing Journal-to-Bearing Clearance 1226

Connecting Rod Bearing Journal-to-Bearing Clearance 1227


Manual
Connecting Rod Bearing Journal Taper and Out-of-Round
1. Measure the crankshaft connecting rod journal diameters in 2 directions perpendicular to one another
at each end of the connecting rod journal. The difference in the measurements from one end to the
other is the taper. Verify measurement is within the wear limit.
Connecting Rod Bearing Journal Taper and Out-of-Round 1228


Manual
Roller Follower Inspection
1. Inspect the roller follower for flat spots or scoring. If any damage is found, inspect the camshaft lobes
and hydraulic lash adjuster for damage.
Roller Follower Inspection 1229


Manual
Hydraulic Lash Adjuster Inspection
1. Inspect the hydraulic lash adjuster and roller follower for damage. If any damage is found, inspect the
camshaft lobes and valves for damage.
Hydraulic Lash Adjuster Inspection 1230


Manual
Valve Stem Diameter
1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter
is within specification.
Valve Stem Diameter 1231


Manual
Valve Stem to Valve Guide Clearance
Special Tool(s)
Clearance Gauge, Valve Guide

303-004 (TOOL-6505-E) or equivalent

NOTE: The valve stem diameter must be within specifications before checking valve stem-to-valve guide
clearance.
1. NOTE: If necessary, use a magnetic base.
Install a Valve Guide Clearance Gauge on the valve stem and install a Dial Indicator Gauge with
Holding Fixture. Lower the valve until the clearance gauge contacts the upper surface of the valve
guide.
2. Move the Valve Guide Clearance Gauge toward the Dial Indicator Gauge with Holding Fixture and
zero the Dial Indicator Gauge. Move the Valve Guide Clearance Gauge away from the Dial Indicator
Gauge with Holding Fixture and note the reading. The reading will be DOUBLE the valve
stem-to-valve guide clearance.
Valve Stem to Valve Guide Clearance 1232

Valve Stem to Valve Guide Clearance 1233


Manual
Valve Inspection
1. Inspect the following valve areas:

1. The end of the stem for grooves or scoring.
2. The valve face and the edge for pits, grooves or scores.
3. The valve head for signs of burning, erosion, warpage and cracking.
4. The valve margin for wear.
Valve Inspection 1234


Manual
Valve Gde Inner Diameter
1. NOTE: Valve guides tend to wear in an hourglass pattern. The ball gauge can be inserted into the
combustion chamber side of the valve guide, if necessary.
Use a ball gauge to determine the inside diameter of the valve guides in 2 directions at the top, middle
and bottom of the valve guide.
2. Measure the ball gauge with a micrometer.
3. If the valve guide is not within specifications, install a new cylinder head assembly.
Valve Gde Inner Diameter 1235


Manual
Valve Spring Installed Length
1. Measure the installed length of each valve spring.
bsp;
Valve Spring Installed Length 1236


Manual
Valve Spring Free Length
1. Measure the free length of each valve spring.
&nbsp
Valve Spring Free Length 1237


Manual
Valve Spring Squareness
1. Measure the out-of-square on each valve spring.

Turn the valve spring and observe the space between the top of the valve spring and the
square.
Valve Spring Squareness 1238


Manual
Valve Spring Strength
Special Tool(s)
Pressure Gauge, Valve/Clutch Spring

303-006 (TOOL-6513-DD) or equivalent
1. Use the Valve/Clutch Spring Pressure Gauge to check the valve spring for correct strength at the
specified valve spring length.
Valve Spring Strength 1239


Manual
Valve Seat Inspection
Valve and Seat Refacing Measurements
NOTE: After grinding valves or valve seats, check valve clearance.
1. Check the valve head and seat.

Check valve angles.
Check margin width.
Be sure margin width is within specification.
2. Inspect for abnormalities on the valve face and seat. Install a new cylinder head assembly if
abnormalities are found.
Valve Seat Inspection 1240


Manual
Valve Seat Width
1. Measure the valve seat width. If necessary, grind the valve seat to specification.
Measure the intake valve seat width.
Measure the exhaust valve seat width.
Recheck the valve spring installed length after the seats have been ground, and shim the valve
springs as necessary to achieve the correct installed spring length.
Depending on the engine,heck the valve lash. Refer to General Procedures in Section 303-01.
Valve Seat Width 1241


Manual
Valve Seat Runout
1. Use a valve seat runout gauge to check valve seat runout.
Valve Seat Runout 1242


Manual
Flexplate Inspection
1. Inspect the flexplate for:

1. any cracks.
2. worn ring gear teeth.
3. chipped or cracked ring gear teeth.
Flexplate Inspection 1243


Manual
Cylinder Head Distortion
Special Tool(s)
Feeler Gauge Set

1. NOTE: Make sure all cylinder head surfaces are clear of any gasket material, silicone sealant, oil and
coolant. The cylinder head surface must be clean and dry before running a flatness check.
NOTE: Use a Straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002
in) per running foot of length, such as Snap-On GA438A or equivalent. For example, if the
Straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from
end to end.
Using a Straightedge and a Feeler Gauge Set, inspect the cylinder head for flatness in the sequence
shown.
Cylinder Head Distortion 1244

Cylinder Head Distortion 1245


Manual
Cylinder Block Distortion
Special Tool(s)
Feeler Gauge Set

1. NOTE: Use a Straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002
end to end.
Use a Straightedge and a Feeler Gauge Set to inspect the cylinder block for flatness.
Cylinder Block Distortion 1246


Manual
Cylinder Bore Cleaning
Material
Item Specification
XO-5W20-QSP (US);
1. NOTICE: If these procedures are not followed, rusting of the cylinder bores may occur.
Clean the cylinder bores with soap or detergent and water.
2. Thoroughly rinse with clean water and wipe dry with a clean, lint-free cloth.
3. Use a clean, lint-freeth and lubricate the cylinder bores.

Use clean engine oil meeting Ford specification.
Cylinder Bore Cleaning 1247


Manual
Core Plug Replacement
Special Tool(s)
Slide Hammer
100-001 (T50T-100-A)
Core Plug Replacement 1248


Manual
Spark Plug Inspection
1. Inspect the spark plug for a bridged gap.

Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil
or carbon fouling.
Install a new spark plug.
2. Check for oil fouling.

Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil
entering the combustion chamber through worn rings and pistons, excessive valve-to-guide
clearance or worn or loose bearings.
Correct the oil leak concern.
3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed
shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner,
too rich a fuel mixture or excessive idling.
Install new spark plugs.
4. Inspect for normal burning.

Check for light tan or gray deposits on the firing tip.
Spark Plug Inspection 1249

5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic
deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing,
wrong type of fuel or the unauthorized installation of a heli-coil insert in place of the spark plug
threads.
6. Inspect for overheating, identified by white or light gray spots and a bluish-burnt appearance of
electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs
with an incorrect heat range, low fuel pump pressure or incorrect ignition timing.
7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters.
These are caused by sudden acceleration.
Install new spark plugs.



Manual
Exhaust Manifold Cleaning and Inspection
Special Tool(s)
Feeler Gauge Set

1. Clean the exhaust manifold using a suitable solvent. Use a plastic scraping tool to clean the gasket
sealing surfaces.
2. NOTE: New exhaust manifold gaskets, studs, nuts and/or bolts must be installed when an exhaust
manifold is serviced.
NOTE: Use a Straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002
end to end.
Using the Straightedge and a Feeler Gauge Set, check the exhaust manifold sealing surface for
warpage. If the warpage is greater than 0.76 mm (0.0299 in), install a new exhaust manifold.
Exhaust Manifold Cleaning and Inspection 1252

Exhaust Manifold Cleaning and Inspection 1253


Manual
Bearing Inspection
1. Inspect bearings for the following defects:

1. Cratering - fatigue failure
2. Spot polishing - incorrect seating
3. Imbedded dirty engine oil
4. Scratching - dirty engine oil
5. Base exposed - poor lubrication
6. Both edges worn - journal damaged
7. One edge worn - journal tapered or bearing not seated
Bearing Inspection 1254


Manual
Powertrain/Drivetrain Mount Neutralizing
NOTE: Refer to the appropriate section and procedure for special instructions on loosening and tightening
mount fasteners.
100-02 .
2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
3. Lower the vehicle.
4. NOTICE: Do not twist or strain the powertrainrivetrain mounts or damage to the mounts may
occur.
Start the vehicle and move it in forward 0.6-1.2 m (2-4 ft). Then move the vehicle in reverse the same
distance.
5. Raise and support the vehicle.
6. Tighten the powertrain/drivetrain mount fasteners.
7. Lower the vehicle.
8. Test the system for normal operation.
Powertrain/Drivetrain Mount Neutralizing 1255

SECTION 303-01: Engine - 5.4L (3V) 2011 Expedition, Navigator Workshop Manual
Material

Capacity
Motorcraft Metal Surface Prep - -
ZC-31-A
Motorcraft Premium Gold WSS-M97B51-A1 a
Engine Coolant
VC-7-B (US); CVC-7-B
(Canada)
Motorcraft SAE 5W-20 WSS-M2C945-A 6.6L (7.0
Premium Synthetic Blend Motor qt.) with
Oil (US); Motorcraft SAE filter
5W-20 Super Premium Motor
Oil (Canada)
XO-5W20-QSP (US);
Motorcraft Specialty Orange WSS-M97B44-D a
Engine Coolant
VC-3-B (US); CVC-3-B
(Canada)
Silicone Brake Caliper Grease ESE-M1C171-A -
and Dielectric Compound
XG-3-A
Silicone Gasket and Sealant WSE-M4G323-A4 -
TA-30
Motorcraft Silicone Gasket -
Remover
ZC-30
TA-26
a Early build vehicle cooling systems are filled with Motorcraft Premium Gold Engine Coolant. Late build
vehicle cooling systems are filled with Motorcraft Specialty Orange Engine Coolant. Do not mix coolant
types. Mixing coolant types degrades the corrosion protection of the coolant. Failure to follow these
instructions may damage the engine or cooling system.
Item Specification
Engine
Displacement 5.4L (330 CID)
Number of cylinders 8
Bore 90.2 mm (3.55 in)
Stroke 105.8 mm (4.17 in)

Firing order 1-3-7-2-6-5-4-8

Spark plug HJFS-24FP-
Minimum oil pressure at idle (engine 172 kPa (25 psi)
at normal operating temperature)
Oil pressure at 2,000 rpm (engine at 275-517 kPa
normal operating temperature)
(40-75 psi)
Compression ratio 9.8:1
Engine weight (without accessory 247 kg (545 lb)
drive components and with flexplat
Engine weight (without accessory 260 kg (574 lb)
drive components and with flywheel)
Cylinder Head and Valve Train
Combustion chamber volume 48.1-51.1 cc
(2.94-3.12 cu in)
Roller follower ratio -
Valve arrangement (front to rear) - LH I-E-I-I-E-I-I-E-I-I-E-I
Valve arrangement (front to rear) - RH I-E-I-I-E-I-I-E-I-I-E-I
Valve guide bore diameter 6.015-6.044 mm (0.237-0.238 in)
Valve stem diameter - intake 5.975-5.995 mm (0.235-0.236 in)
Valve stem diameter - exhaust 5.95-5.97 mm (0.234-0.235 in)
Valve stem-to-guide clearance - intake 0.020-0.045 mm (0.001-0.002 in)
Valve stem-to-guide clearance - 0.069-0.094 mm (0.003-0.004 in)
exhaust
Valve head diameter - intake 33.62-33.98 mm (1.324-1.338 in)
Valve head diameter - exhaust 37.32-37.68 mm (1.469-1.483 in)
Valve face runout 0.05 mm (0.002 in)
Valve seat width - intake 1.2-1.4 mm
(0.047-0.055 in)
Valve seat width - exhaust 1.4-1.6 mm
(0.055-0.063 in)
Valve seat angle 44.5-45.0 degrees
Valve spring free length 55.7 mm (2.19 in)
Valve spring compression pressure 350 N (79 lb) 17.5 N (4 lb) @ 42.04 mm
(1.66 in)
Valve spring installed height 42.04 mm (1.66 in)
Valve spring installed pressure 350 N (79 lb) 17.5 N (4 lb) @ 42.04 mm
(1.66 in)
Head gasket surface flatness 0.025 mm (0.001 in) in any 25 mm (1 in) x 25 mm (1 in) area; 0.05
mm (0.002 in) in any 150 mm (6 in) x 150 mm (6 in) area; 0.1 mm
(0.004 in) overall
Hydraulic Lash Adjuster

Diameter 15.988-16.000 mm (0.6294-0.6299 in)

Clearance-to-bore 0.018-0.069 mm (0.0007-0.0027 in)
Service limit -
Hydraulic leak down rate 5-25 seconds a
Collapsed lash adjuster gap 0.45-0.85 mm (0.017-0.033 in)
Camshaft
Theoretical valve lift @ 0 lash - intake 11.1 mm (0.437 in)
Theoretical valve lift @ 0 lash - 11.0 mm (0.433 in)
exhaust
Lobe lift - intake 5.520 mm (0.217 in)
Lobe lift - exhaust 5.506 mm (0.217 in)
Allowable lobe lift loss 0.127 mm (0.005 in)
Journal diameter 28.607-28.633 mm (1.126-1.127 in)
Camshaft journal bore inside diameter 28.657-28.682 mm (1.128-1.129 in)
Camshaft journal-to-bearing clearance 0.024-0.075 mm (0.001-0.003 in)
Runout 0.03 mm (0.001 in)
End play 0.027-0.190 mm (0.001-0.007 in)
Cylinder Block
Cylinder bore diameter - grade 1 90.200-90.210 mm (3.5512-3.5516 in)
0.006 mm (0.0002 in)
Cylinder bore maximum out-of-round 0.020 mm (0.0008 in)
Main bearing bore inside diameter 72.400-72.424 mm (2.850-2.851 in)
Head gasket surface flatness 0.03 mm (0.001 in) in any 40 mm (1.5 in) x 40 mm (1.5 in) area;
0.05 mm (0.002 in) in any 150 mm (6 in) x 150 mm (6 in) area; 0.15
mm (0.006 in) overall
Crankshaft
Main bearing journal diameter 67.481-67.505 mm (2.6568-2.6576 in)
Main bearing journal maximum taper 0.004 mm (0.0002 in)
Main bearing journal maximum 0.0075 mm (0.0003 in) between cross sections
out-of-round
Main bearing journal-to-cylinder block 0.024-0.048 mm (0.0009-0.0019 in)
clearance
Connecting rod journal diameter 52.983-53.003 mm (2.0859-2.0867 in)
Connecting rod journal maximum 0.004 mm (0.0002 in)
taper
Connecting rod journal maximum 0.0075 mm (0.0003 in) between cross sections
out-of-round
Crankshaft maximum end play 0.075-0.377 mm (0.0030-0.0148 in)
Piston and Connecting Rod
Piston diameter - grade 1 (at right 90.165-90.175 mm (3.5498-3.5502 in)
angle to pin bore)
angle to pin bore)


angle to pin bore)
Piston-to-cylinder bore clearance (at 0.025-0.045 mm (0.0010-0.0018 in)
grade size)
Piston ring end gap - top 0.15-0.30 mm (0.006-0.012 in)
Piston ring end gap - intermediate 0.25-0.50 mm (0.0098-0.0197 in)
Piston ring end gap - oil control 0.15-0.65 mm (0.0059-0.0256 in)
Piston ring groove width - top 1.52-1.55 mm (0.0598-0.0610 in
Piston ring groove width - intermediate 1.52-1.54 mm (0.0598-0.0606 in)
Piston ring groove width - oil control 3.030-3.050 mm (0.1193-0.1201 in)
Piston ring width - top and 1.47-1.50 mm (0.0578-0.0590 in)
intermediate
Piston ring-to-groove clearance - top 0.020-0.080 mm (0.0008-0.0031 in)
Piston ring-to-groove clearance - 0.030-0.070 mm (0.00>
intermediate
Piston pin bore diameter 22.008-22.014 mm (0.8665-0.8667 in)
Piston pin diameter 22.0010-22.0030 mm (0.8662-0.8663 in)
Piston pin length 61.8 mm (2.433 in)
Piston pin-to-piston fit 0.005-0.0130 mm (0.0002-0.0005 in)
Connecting rod-to-pin clearance 0.009-0.0235 mm (0.0004-0.0093 in)
Connecting rod pin bore diameter 22.012-22.024 mm (0.8666-0.8671 in)
Connecting rod length 169.1 mm (6.6575 in)
(center-to-center)
Connecting rod maximum allowed 0.038 mm (0.0015 in)
bend
Connecting rod maximum allowed 0.05 mm (0.0020 in)
twist b
Connecting rod bearing bore diameter 53.027-53.049 mm (2.0877-2.0885 in)
(with assembled liners)
Connecting rod bearing-to-crankshaft 0.026-0.064 mm (0.0010-0.0025 in)
clearance
Connecting rod side clearance 0.125-0.475 mm (0.0049-0.0187 in)
a The time required for the plunger to leak down 1.6 mm (0.062 in) of travel with 222 N force and leak-down
fluid in the lash adjuster.

b The pin bore and crank bearing bore must be parallel and in the same vertil plane within the specified total
difference when measured at the ends of a 203 mm bar, 105.5 mm on each side of rod centerline.

A/C compressor bolts 25 18 -
Accessory drive belt tensioner bolt 25 18 -
Air intake resonator assembly bolt 10 - 89
Air Cleaner (ACL) outlet pipe-to-Throttle Body (TB) adapter bolt 10 - 89
Axle carrier mounting bushing bolts 115 85 -

Camshaft bearing cap bolts a - - -

Camshaft phaser and sprocket bolts a - - -
Camshaft Position (CMP) sensor bolt - 89
Coolant crossover manifold assembly bolts 10 - 89
Coolant pump bolts 25 18 -
Coolant pump pulley bolts 25 18 -
Coolant tube stud bolt 10 - 89
Connecting rod bolts a - - -
Crankshaft pulley bolt a - - -
Crankshaft main bearing bolts (cross-mounted) a - - -
Crankshaft main bearing bolts (vertical) a - - -
Crankshaft Position (CKP) sensor bolt 10 - 89
Crankshaft rear seal retainer plate bolts a - -
Cylinder block drain plugs 20 - 177
Cylinder head bolts a - - -
Cylinder Head Temperature (CHT) sensor 10 - 89
Drive belt idler pulley bolt 25 18 -
Engine front cover bolts a - - -
Engine Oil Pressure (EOP) switch 18 - 159
Engine support insulator-to-cylinder block bolts 63 46 -
Engine support insulator through bolt 350 258 -
Engine support insulator-to-frame bolts 175 129 -
Engine support insulator-to-frame nuts 129 -
Engine support insulator-to-frame stud bolt 15 - 133
Evaporative Emission (EVAP) purge valve support bracket bolt 10 - 89
Exhaust manifold heat shield bolts 13 - 115
Exhaust manifold nuts a - - -
Exhaust manifold studs 12 - 106
Exhaust manifold-to-Y-pipe nuts 40 30 -
Flexplate bolts a - - -
Flexplate inspection cover bolts 34 25 -
Front frame crossmember bolts 90 66 -
Fuel rail bolts 10 89
Ground strap bolt 10 - 89
Hood bolts 12 - 106
Ignition coil 6 - 53
Intake manifold-to-cylinder head bolts a - - -
Intake manifold vacuum tube support bracket nut 10 - 89
Knock Sensor (KS) bolts 20 - 177
Oil filter 15 - 133
Oil filter adapter bolts 25 18 -
Oil level indicator tube bolt 10 - 89
Oil pan bolts a - - -
Oil drain plug 17 -

Oil pump bolts 10 - 89

Oil pump screen and pickup tube bolts 10 - 89
Oil pump screen and pickup tube spacer 25 18 -
Oil pump screen and pickup tube support bracket bolt 25 18 -
PCV fitting bolts 6 - 53
Power steering fluid return tube bolt 23 17 -
Power Steering Pressure (PSP) hose support bracket nut 10 - 89
Power steering pump bolts 25 18 -
Radio ignition interference capacitor nut 25 18 -
Rear seal retainer plate bolts a - -
Skid plate bolts 48 35 -
Spark plug 12 - 106
Starter wiring harness rear support bracket bolt 10 - 89
Steering shaft bolt 30 22 -
Thermostat housing bolts 10 - 89
Timing chain guide bolts 10 - 89
Timing chain hydraulic tensioner bolts 25 18 -
Torque converter-to-flexplate nuts 36 27 -
Transmission fluid cooler tube support bracket nut 10 - 89
Transmission fluid cooler tube rear support bracket bolt 48 -
Transmission mount-to-crossmember nuts 103 76 -
Transmission-to-engine bolts 48 35 -
Throttle Body (TB) bolts a - - -
Valve cover bolts a - - -
Variable Camshaft Timing (VCT) housing bolts 10 - 89
Wiring harness ground strap 10 - 89
a Refer to the procedure in this section.

Engine
NOTE: Refer to the exploded view under the Assembly procedure in this section.
The 5.4L (3V) is a V-8 engine with the following features:
Single overhead camshafts

Three valves per cylinder
Sequential Multi-Port Fuel Injection (SFI)
Aluminum cylinder heads
Cast iron, 90-degree V-cylinder block
Variable Camshaft Timing (VCT)
Individually chain-driven camshafts with a hydraulic timing chain tensioner on each timing chain
Distributorless ignition system
Electronic Returnless Fuel System (ERFS)
Engine Identification
Always refer to these labels when installation of new parts is necessary, or when checking engine calibrations.
The engine parts often differ within a CID family. Verification of the identification codes will make sure that
the correct parts are obtained. These codes contain all the pertinent information relatingthe dates, optional
equipment and revisions. The Ford Master Parts Catalog contains a complete listing of the codes and their
application.
Engine Code Information Label
The engine code information label, located on the front side of the valve cover, contains the following:
Item Description
1 Engine part number
2 Bar code
3 Running number
4 Engine build date (DDMMYY)
5 Windsor engine plant
6 Bar code
7 Engine displacement
Engine Cylinder Identification
Engine 1262
Exhaust Emission Control System
Operation and necessary maintenance of the exhaust emission control devices used on this engine are covered
in the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Induction System
The SFI system provides the fuel/air mixture needed for combustion in the cylinders. The 8 solenoid-operated
fuel injectors:
are mounted in the intake manifold.

meter fuel into the air intake stream in accordance with engine demand.
are positioned so that their tips direct fuel just ahead of the engine intake valves.
supply fuel from the fuel tank with a fuel pump mounted in the fuel tank.
Valve Train
The valve train operates as follows:
Ball-tip hydraulic lash adjusters provide automatic lash adjustment.

Roller followers ride on the camshaft lobe, transferring the up-and-down motion of the camshafts to
the valves in the cylinder heads.
PCV System
All engines are equipped with a closed-type PCV system recycling the crankcase vapors to the upper intake
manifold.
Lubrication System
The engine lubrication system operates as follows:
Oil is drawn into the oil pump through the oil pump screen cover and tube in the sump of the oil pan.
Oil is pumped through the oil filter on the left front side of the cylinder block.
Engine 1263
Oil enters the main gallery where it is distributed to the crankshaft main journals and to both cylinder
heads.
From the main journals, the oil is routed through cross-drilled passages in the crankshaft to lubricate
the connecting rod bearings. Controlled leakage through the crankshaft main bearings and connecting
rod bearings is slung radially outward to cool and lubricate the cylinder walls as well as the entire
connecting rod, piston and piston ring assembly.
The left cylinder head is fed from a drilling into the supply passage feeding the main gallery at the
front of the cylinder block. The right cylinder head is fed from a drilling into the rear of the main
gallery. Main gallery pressure is reduced as it enters the cylinder head galleries through fixed
serviceable orifices, located at the upper part of the feed passages. It is this reduced pressure in the
cylinder head galleries which feeds the camshaft journals, the hydraulic lash adjusters and the primary
and secondary timing chain tensioners.
The oil pressure feed for the VCT solenoids, VCT housings and camshaft phaser and sprockets is not
reduced.
The camshaft lobe and roller followers are lubricated by splash created through valve train operation.
Engine Oil Flow Illustrations
Engine Assembly

1 6731 Oil filter
2 6A642 Oil cooler (if equipped)
3 9278 Engine Oil Pressure (EOP) switch
4 6881 Oil filter adapter
Engine Assembly 1264

5 6622 Oil pump screen and pickup tube

6 6600 Oil pump
7 6L266A Timing chain tensioner - RH
8 6C260 Variable Camshaft Timing (VCT) housing - RH
9 6M280 VCT oil control solenoid assembly - RH
10 - Front camshaft bearing cap - RH (part of 6049)
11 6L266 Timing chain tensioner - LH
12 6C261 VCT housing - LH
13 6M280 VCT oil control solenoid assembly - LH
14 - Front camshaft bearing cap - LH (part of 6049)
15 6049 Cylinder head - LH
Camshaft Phaser and Sprocket, Camshaft Phaser and Sprocket Bolt and Camshaft

1 6279 Camshaft phaser and sprocket bolt
2 - Camshaft phaser and sprocket (part of 6A257)
3 6250 Camshaft
LH Variable Camshaft Timing (VCT) Housing, VCT Solenoid and Timing Chain Tensioner
Camshaft Phaser and Sprocket, Camshaft Phaser and Sprocket Bolt and Camshaft 1265

1 6L266 Timing chain tensioner - LH
2 6C261 Variable Camshaft Timing (VCT) housing - LH
3 6M280 VCT oil control solenoid assembly - LH
RH Variable Camshaft Timing (VCT) Housing and VCT
Solenoid
1 - Front camshaft bearing cap - RH (part of 6049)
2 6C260 Variable Camshaft Timing (VCT) housing - RH
3 6M280 VCT oil control solenoid assembly - RH
LH Variable Camshaft Timing (VCT) Housing, VCT Solenoid and Timing Chain Tensioner 1266
Variable Camshaft Timing (VCT) Housing

1 6M280 Variable Camshaft Timing (VCT) oil control
solenoid assembly
2 - VCT housing
Oil Pump
The lubrication system is designed to provide optimum oil flow to critical components of the engine through
its entire operating range. The heart of the system is a positive displacement internal gear oil pump using top
seal rotors. Generically this design is known as a gerotor pump, which operates as follows:
The oil pump is mounted on the front face of the cylinder block.
The inner rotor is piloted on the crankshaft post and is driven through flats on the crankshaft.
System pressure is limited by an integral, internally-vented relief valve which directs the bypassed oil
back to the inlet side of the oil pump.
Oil pump displacement has been selected to provide adequate volume to make sure of correct oil
pressure, both at hot idle and maximum speed.
The relief valve calibration protects the system from excessive pressure during high viscosity
conditions.
The relief valve is designed to provide adequate connecting rod bearing lubrication under
high-temperature and high-speed conditions.
Variable Camshaft Timing (VCT) Housing 1267


Engine
For basic engine mechanical concerns, refer to Section 303-00 . For driveability concerns, refer to the
Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Engine 1269
IN-VEHICLE REPAIR Procedure revision date: 08/12/2010
Intake Manifold
Material
Item Specification
ZC-31-A
Motorcraft Silicone Gasket Remover -
ZC-30
Air Cleaner (ACL) Outlet Pipe-To-Throttle Body (TB) Adapter and Air Intake Resonator Assembly
Part
1 6758 Crankcase ventilation tube
2 - Throttle Body (TB) ad intake resonator assembly clamp
(part of 9F763)
3 W505427 Air intake resonator assembly bolt
4 9F763 Air intake resonator assembly
5 W713555 Air Cleaner (ACL) outlet pipe-to- TB adapter bolt (3
required)
6 9A589 ACL outlet pipe-to- TB adapter
7 9628 ACL outlet pipe-to- TB adapter seal
Throttle Body (TB) and Ignition Coil Electrical Connectors
Intake Manifold 1270

Part
1 18472 Heater coolant hose
2 6A664 PCV tube
3 - Thrtle Position (TP) sensor electrical connector (part of
9D930)
4 - Electronic Throttle Control (ETC) electrical connector
(part of 9D930)
5 - Fuel injector electrical connectors (part of 9D930) (8
required)
Intake Manifold Vacuum Tube Assembly
Throttle Body (TB) and Ignition Coil Electrical Connectors 1271

Part
1 - LH Knock Sensor (KS) electrical connector (part of
9D930)
2 - RH KS electrical connector (part of 9D930)
3 - Cylinder Head Temperature (CHT) electrical connector
(part of 9D930)
4 - Electrical wiring harness retainer (part of 9D930)
5 9C490 Brake booster vacuum hose
6 9A474 Intake manifold vacuum tube assembly
Intake Manifold, Coolant Crossover Manifold Assembly and Gaskets
Intake Manifold Vacuum Tube Assembly 1272

Part
1 - Variable Camshaft Timing (VCT) solenoid electrical
connector (part of 9D930)
2 - Engine wiring harness retainers (part of 9D930) (2
required)
3 W710758 Intake manifold bolt (10 required)
4 9424 Intake manifold
5 9439 RH intake manifold gasket
6 9439 LH intake manifold gasket
7 W503282 Coolant crossover manifold assembly bolt (3 required)
8 8C368 Coolant crossover manifold assembly
9 8C387 RH coolant crossover manifold assembly gasket
10 8C387 LH coolant crossover manifold assembly gasket
Removal
1. Drain the cooling system. For additional information, refer to Section 303-03 .
2. Remove the generator. For additional information, refer to Section 414-00 .
3. Disconnect the quick connect couplings and remove the crankcase ventilation tube. For additional
Intake Manifold, Coolant Crossover Manifold Assembly and Gaskets 1273

4. Remove the bolt, loosen the clamp and remove the air intake resonator assembly.
5. Remove the 3 bolts and the Throttle Body (TB)-to-Air Cleaner (ACL) outlet tube adapter.
6. Disconnect the quick connect couplings and remove the PCV tube. For additional information, refer
to Section 310-00 .
7. Disconnect the fuel supply tube quick connect coupling. For additional information, refer to Section
310-00 .
8. Disconnect the electrical connector and the Evaporative Emission (EVAP) tube quick connect
coupling from the EVAP canister purge valve. For additional information, refer to Section 310-00 .
9. Disconnect the heater coolant hose from the coolant crossover manifold assembly.
10. Disconnect the 8 fuel injector electrical connectors.
11. Disconnect the Throttle Position (TP) sensor and Electronic Throttle Control (ETC) electrical
connectors.
12. Disconnect the 4 LH ignition coil and the LH Variable Camshaft Timing (VCT) solenoid electrical
connectors and detach the 2 engine wiring harness retainers from the LH valve cover studs.
13. Disconnect the intake manifold vacuum tube from the brake booster vacuum hose.
14. NOTE: The intake manifold vacuum tube must be removed with the intake manifold as an assembly.
Disconnect the intake manifold vacuum tube from the LH valve cover studbolt and the support
bracket at the rear of the LH cylinder head.
15. Remove the 10 intake manifold bolts.
16. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These tools cause scratches and gouges which make leak
paths. Use a plastic scraping tool to remove all traces of old sealant.
NOTE: Do not disconnect the upper radiator hose unless servicing the thermostat housing or coolant
crossover.
Remove the 3 bolts and position the engine coolant crossover assembly aside.
Discard the gaskets and clean and inspect the sealing surfaces with metal surface prep. Follow
the directions on the packaging.
17. NOTE: The intake manifold vacuum tube must be positioned under the engine wiring harness and
removed with the intake manifold as an assembly.

Position the intake forward to gain access to the wiring harness retainers.
18. Disconnect the 2 engine wiring harness retainers from the rear of the intake manifold.
19. Disconnect the Cylinder Head Temperature (CHT) sensor jumper harness electrical connector
retainer.
NOTE: The intake manifold vacuum tube must be positioned under the engine wiring harness and
removed with the intake manifold as an assembly.
Remove the intake manifold and discard the gaskets.
Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep.
Follow the directions on the packaging.
Installation
1. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically
including valve or piston damage, check the intake manifold for metal debris. If metal debris is
found, install a new intake manifold. Failure to follow these instructions can result in engine
damage.
NOTE: The intake manifold vacuum tube must be positioned under the engine wiring harness during
installation of the intake manifold.
Using new intake manifold gaskets, position the intake manifold.
2. Position the intake manifold forward and connect the CHT sensor jumper harness electrical connector
retainer.
3. Connect the 2 engine wiring harness retainers to the rear of the intake manifold and position back the
intake manifold assembly.
4. Using new gaskets, position the coolant crossover manifold assembly and install the 3 bolts.
5. Install the 10 intake manifold bolts and tighten in 2 stages in the sequence shown.
Stage 1: Tighten to 2 Nm (18 lb-in).

6. Connect the intake manifold vacuum tube to the support bracket and the valve cover stud.
7. Connect the brake booster vacuum hose to the intake manifold vacuum tube and position the clamp.
8. Connect the 4 LH ignition coil and the LH VCT solenoid electrical connectors and attach the 2 engine
wiring harness retainers to the LH valve cover studs.
9. Connect the TP sensor and electronic throttle control electrical connectors.
10. Connect the 8 fuel injector electrical connectors.
11. Connect the heater coolant hose to the coolant crossover manifold assembly.
12. Connect the electrical connector and the EVAP tube quick connect coupling to the EVAP canister
purge valve. For additional information, refer to Section 310-00 .
13. Connect the fuel supply tube quick connect coupling. For additional information, refer to Section
310-00 .
14. Position the PCV tube and connect the quick connect couplings. For additional information, refer to
Section 310-00 .
15. Position the TB -to- ACL outlet tube adapter and install the 3 bolts.
Tighten the bolt to 10 Nm (89 lb-in).
16. Position the air intake resonator assembly, install the bolt and the clamp.
Tighten the bolt to 10 Nm (89 lb-in).
17. Position the crankcase ventilation tube and connect the quick connect couplings. For additional
18. Install the generator. For additional information, refer to Section 414-00 .

19. Fill and bleed the engine cooling system. For additional information, refer to Section 303-03 .

Valve Cover - LH
PCV Tube, Engine Wiring Harness Retainers and Variable Camshaft Timing (VCT) Solenoid Electrical Connector
Part
1 6A664 PCV tube
2 - Variable Camshaft Timing (VCT) solenoid electrical
3 - Engine wiring harness retainers (part of 9D930)
4 N605892 Oil level indicator and tube bolt
5 6K873 Oil level indicator and tube
Engine Wiring Harness Retainers, Intake Manifold, LH Valve Cover and Gasket
Valve Cover - LH 1278


1 - Engine wiring harness retainers (part of 9D930)
2 - Intake manifold vacuum tube-to-brake booster hose
3 9D446 Intake manifold vacuum tube
4 6A505 LH valve cover
5 6A559 LH valve cover gasket
Removal
1. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Section 303-12 .
2. Remove the bolt and position the oil level indicator and tube aside.
to Section 310-00 .
4. Disconnect the intake manifold vacuum tube hose from the brake booster.
5. Disconnect the intake manifold vacuum tube from the support bracket and the valve cover stud.
6. Disconnect the Variable Camshaft Timing (VCT) solenoid electrical connector.
7. Disconnect the 3 wiring harness retainers from the front of the LH valve cover and the 2 wiring
harness retainers from the LH valve cover studs.
8. Remove the 4 LH ignition coils. For additional information, refer to Section 303-07 .
NOTICE: When removing the valve cover, make sure to avoid damaging the Variable Camshaft
Timing (VCT) solenoid.
Engine Wiring Harness Retainers, Intake Manifold, LH Valve Cover and Gasket 1279
NOTE: The fasteners are part of the valve cover and should not be removed.
Loosen the 10 fasteners and remove the LH valve cover and gasket.
Clean the valve cover mating surface of the cylinder head with silicone gasket remover and
metal surface prep. Follow the directions on the packaging.
Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a
suitable solvent.
Installation
1. NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the
sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the
packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to
follow this procedure can cause future oil leakage.
Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the
cylinder head.
2. NOTICE: When installing the valve cover, make sure to avoid damaging the Variable Camshaft
Position the LH valve cover and new gasket on the cylinder head and tighten the 9 fasteners in the
sequence shown.
3. Position the intake manifold vacuum tube assembly onto the support bracket and the valve cover stud.
4. Connect the intake manifold vacuum tube hose to the brake booster.
5. Install the 4 LH ignition coils. For additional information, refer to Section 303-07 .
6. Connect the 3 wiring harness retainers to the front of the RH valve cover and the 2 wiring harness
retainers to the RH valve cover studs.
7. Connect the VCT solenoid electrical connector.
Section 310-00 .
9. Position back the oil level indicator and tube and install the bolt.
10. Install the ACL outlet pipe. For additional information, refer to Section 303-12 .
Valve Cover - RH
Material
Item Specification
ZC-31-A
TA-30
Remover
ZC-30
Engine Wiring Harness Retainers, Variable Camshaft Timing (VCT) Solenoid Electrical Connector, Crankcase
Ventilation Tube, RH Valve Cover and Gasket

1 - le Camshaft Timing (VCT) solenoid
electrical connector (part of 19D930)
2 - Engine wiring harness
retainers (part of 19D930)
3 - Engine wiring harness
retainers (part of 19D930)
5 6582 RH valve cover
Valve Cover - RH 1282

6 6584 RH valve cover gasket

Removal
Vehicles with auxiliary heat
1. Drain the cooling system. For additional information, refer to Section 303-03 .
2. Disconnect the 2 auxiliary heat coolant hoses and position the auxiliary heat coolant hoses aside.
All vehicles
3. Disconnect the quick connect couplings and remove the crankcase vent tube. For additional
information, refer to Sectio0-00 .
4. Disconnect the PCM electrical connector and position aside.
5. Remove the nut and the ground cable and disconnect the wiring harness retainer.
6. Disconnect the PCM electrical connector.
7. Disconnect the 2 electrical connectors and the wiring harness retainer and position the wiring harness
aside.
Engine Wiring Harness Retainers, Variable Camshaft Timing (VCT) Solenoid Electrical Connector,
1283 Crankcas
8. Disconnect the RH radio ignition interference capacitor and engine cooling fan clutch electrical
connectors.
9. Remove the 4 RH ignition coils. For additional information, refer to Section 303-07 .
10. Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector.
11. Disconnect the 2 engine wiring harness retainers from the RH valve cover studs and position the
wiring harness aside.
NOTICE: When removing the valve cover, make sure to avoid damaging the Variable Camshaft
NOTE: The fasteners are part of the valve cover and should not be removed.
Loosen the 9 fasteners and remove the RH valve cover and gasket.
Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a
suitable solvent.
Installation
All vehicles
1. NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the
sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the
packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to
follow this procedure can cause future oil leakage.
Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the
cylinder head.
1284 Crankcas
Position the RH valve cover and new gasket on the cylinder head and tighten the 8 fasteners in the
sequence shown.
3. Install the 4 RH ignition coils. For additional information, refer to Section 303-07 .
4. Position back the engine wiring harness and connect the 2 electrical connectors and the wiring harness
retainer.
5. Connect the PCM electrical connector.
6. Connect the wiring harness retainer and ground cable and install the nut.
1285 Crankcas
7. Connect the PCM electrical connector.
8. Connect the RH radio ignition interference capacitor and engine cooling fan clutch electrical
connectors.
9. Connect the RH VCT solenoid electrical connector.
10. Connect the wiring harness retainers to the valve cover.
11. Position the crankcase vent tube and connect the quick connect couplings. For additional information,
Vehicles with auxiliary heat
12. Connect the 2 auxiliary heat coolant hoses.
13. Fill and bleed the coolant system. For additional information, refer to Section 303-03 .
1286 Crankcas
1287 Crankcas
SECTION 303-01: Engine 5.4L (3V) 2011 Expedition, Navigator Workshop Manual
Crankshaft Pulley
Special Tool(s)
3 Jaw Puller
303-D121 or equivalent
Installer, Crankshaft Vibration Damper

303-102 (T74P-6316-B)
Material
Item Specification
Motorcraft Metal Surface Prep
ZC-31-A
5W-20 Super Premium Motor Oil
(Canada)
XO-5W20-QSP (US);
TA-30
Motorcraft Silicone Gasket
Remover
ZC-30

1 8620 Accessory drive belt
2 W701512 Crankshaft pulley bolt
3 N806165 Crankshaft pulley bolt washer
4 6316 Crankshaft pulley
Removal
Crankshaft Pulley 1288

100-02 .
2. Rotate the tensioner clockwise and remove the accessory drive belt from the crankshaft pulley.
3. Remove the crankshaft pulley bolt and washer.

Discard the crankshaft pulley bolt.
4. Using the 3 Jaw Puller, remove the crankshaft pulley.
Installation
1. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned
with metal surface prep and silicone gasket remover. Allow to dry until there is no sign of wetness, or
4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
2. Lubricate the crankshaft pulley sealing area with clean engine oil prior to installation.
3. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.

4. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages.
Stage 1: Tighten to 90 Nm (66 lb-ft).
Stage 2: Loosen 360 degrees.
Stage 4: Tighten an additional 90 degrees.
5. Rotate the tensioner clockwise and install the accessory drive belt onto the crankshaft pulley.

Crankshaft Front Seal
Special Tool(s)
3 Jaw Puller
Installer, Crankshaft Front Oil Seal

303-635

303-102 (T74P-6316-B)
Installer, Front Cover Oil Seal

303-335 (T88T-6701-A)
Remover, Crankshaft Front Oil Seal

303-107 (T74P-6700-A)
Material
Item Specification
ZC-31-A
(Canada)
XO-5W20-QSP (US);
TA-30
Remover
ZC-30
Crankshaft Front Seal 1291


2 W701512 Crankshaft pulley bolt
3 N806165 Crankshaft pulley bolt washer
5 6700 Crankshaft front seal
Removal
100-02 .
2. Rotate the tensioner clockwise and remove the accessory drive belt from the crankshaft pulley.

4. Using the 3 Jaw Puller, remove the crankshaft pulley.
5. Using the Crankshaft Front Oil Seal Remover, remove and discard the crankshaft seal.
Installation

1. Lubricate the engine front cover and the new crankshaft seal inner lip with clean engine oil.
2. Using the Crankshaft Front Oil Seal Installer, the Crankshaft Vibration Damper Installer and the Front
Cover Oil Seal Installer, install the new crankshaft front seal into the engine front cover.

6. Rotate the tensioner clockwise and install the accessory drive belt onto the crankshaft pulley.

Engine Front Cover
Special Tool(s)
3 Jaw Puller

303-635

303-102 (T74P-6316-B)

303-335 (T88T-6701-A)

303-107 (T74P-6700-A)

Material
Item Specification
ZC-31-A
(Canada)
XO-5W20-QSP (US);
Silicone Gasket and WSE-M4G323-A4
Sealabr>TA-30
Remover
ZC-30
Engine Front Cover 1295

Front End Accessory Drive (FEAD), LH and RH Camshaft Position (CMP) Sensors Electrical Connectors
Part
2 N808102 Accessory drive belt idler pulley bolt
3 6C348 Accessory drive belt idler pulley
5 8678 Accessory drive belt idler pulley
6 N808920 Accessory drive belt tensioner bolt (3 required)
7 6B209 Accessory drive belt tensioner
9 8678 Accessory drive belt idler pulley
10 - RH Camshaft Position (CMP) sensor electrical
11 - LH CMP sensor electrical connector (part of 1
Radio Ignition Interference Capacitors, Coolant Pump Pulley, Crankshaft Pulley and Front Oil Pan Bolts
Front End Accessory Drive (FEAD), LH and RH Camshaft Position (CMP) Sensors Electrical Connectors
1296

1 6A340 Crankshaft pulley bolt
2 6378 Crankshaft pulley bolt washer
5 N806282 Coolant pump pulley bolt (4 required)
6 8A528 Coolant pump pulley
7 W701605 Oil pan bolt (4 required)
8 W500110 RH radio ignition interference capacitor bolt
9 18801 RH radio ignition interference capacitor
10 W500110 LH radio ignition interference capacitor bolt
11 18801 LH radio ignition interference capacitor
Engine Front Cover, Gaskets and Crankshaft Position (CKP) Sensor Electrical Connector
Radio Ignition Interference Capacitors, Coolant Pump Pulley, Crankshaft Pulley and Front Oil Pan
1297
Bolts
Part
1 - Crankshaft Position (CKP) sensor electrical connector
(part of 9D930)
2 W706605 Engine front cover bolt
3 N808529 Engine front cover studs (2 required)
4 N806177 Engine front cover bolt (9 required)
5 W709573 Engine front cover stud (3 required)
6 6019 Engine front cover
7 6020 Engine front cover gasket (3 required)
Removal
100-02 .
2. Remove the RH valve cover. For additional information, refer to Valve Cover - RH in this section.
3. Remove the LH valve cover. For additional information, refer to Valve Cover - LH in this section.
4. Loosen the 4 coolant pump pulley bolts.
5. Rotate the tensioner clockwise and remove the accessory drive belt.
6. Remove the 4 bolts and the coolant pump pulley.
7. Drain the engine oil.
8. Remove the bolt and position the starter wiring harness and starter wiring harness rear support bracket
aside.
9. Remove the nut and position aside the transmission cooler tube support bracket and the starter wiring
harness support bracket.
Engine Front Cover, Gaskets and Crankshaft Position (CKP) Sensor Electrical Connector 1298
10. Disconnect the Crankshaft Position (CKP) sensor electrical connector.

11. Remove the nut and position aside the Power Steering Pressure (PSP) hose support bracket.

13. Remove and discard the crankshaft pulley bolt. Using the 3 Jaw Puller, remove the crankshaft
pulley.
14. Using the Crankshaft Front Oil Seal Remover, remove and discard the crankshaft front seal.
15. Remove the 3 bolts and the 3 accessory drive idler pulleys.
16. Remove the 3 bolts and the accessory drive belt tensioner.
17. If equipped, remove the 4 bolts and the skid plate.
18. Remove the 4 front oil pan bolts.
19. Disconnect the wiring harness retainer from the power steering pump stud bolt.
20. Remove the stud bolt, the 2 bolts, and position aside the power steering pump.
21. Disconnect the RH Camshaft Position (CMP) sensor electrical connector.
22. Remove the nut and position the RH radio ignition interference capacitor aside.
23. Disconnect the LH CMP sensor electrical connector.
24. Remove the nut and position the LH radio ignition interference capacitor aside.
25. Remove the 10 bolts and the 5 studs.
26. Remove the engine front cover from the front cover-to-cylinder block dowel.
Remove the engine front cover gaskets.
27. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other
abrasive means to clean the sealing surfaces. These tools cause scratches and gouges
which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the
directions on the packaging.
Inspect the mating surfaces.

Installation
1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other
abrasive means to clean the sealing surfaces. These tools cause scratches and gouges
NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be
removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover
and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes,
whichever is longer. Follow the directions on the packaging. Failure to follow this procedure
can cause future oil leakage.
NOTE: Make sure that the engine front cover gasket is in place on the engine front cover
before installation.
Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface
and the oil pan-to-cylinder block surface, at the locations shown.
2. Install a new engine front cover gasket on the engine front cover. Position the engine front
cover onto the dowels. Install the fasteners finger-tight.
3. Tighten the 15 engine front cover fasteners in the sequence shown in 2 stages.
Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 lb-ft).
Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).

1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
6 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
12 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
15 W706605 Bolt, Hex Head Pilot, M8 x 1.25 x 56
4. Loosely install the 4 oil pan bolts, then tighten in 2 stages, in the sequence shown.
5. Connect the CKP sensor electrical connector.

6. Position the starter wiring harness support bracket and the transmission cooler tube support
bracket and tighten the nut.
7. Position the starter wiring harness and starter wiring harness rear support bracket and install
the bolt.
8. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.
9. Using the Crankshaft Vibration Damper Installer, Front Cover Oil Seal Installer and the
Crankshaft Front Oil Seal Installer, install a new crankshaft front seal into the engine front
cover.
10. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area
cleaned with metal surface prep and silicone gasket remover. Allow to dry until there is no
sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause
future oil leakage.
11. Use the Crankshaft Vibration Damper Installer to install the crankshaft pulley.
12. Tighten the new crankshaft pulley bolt in 4 stages.

13. Install the accessory drive belt tensioner and the 3 bolts.
14. Install the 3 accessory drive idler pulleys and the 3 bolts.
15. Position the coolant pump pulley and install the 4 bolts finger-tight.
16. If equipped, install the skid plate and the 4 bolts.
17. Position the power steering pump and install the stud bolt and the 2 bolts.
18. Attach the engine wiring harness to the power steering pump stud bolt.
19. Position the PSP hose support bracket and install the nut.
20. Connect the RH CMP sensor electrical connector.

21. Install the LH radio ignition interference capacitor and the nut.
22. Connect the LH CMP sensor electrical connector.
23. Install the RH radio ignition interference capacitor and the nut.
24. Rotate the tensioner clockwise and install the accessory drive belt.
25. Tighten the 4 coolant pump pulley bolts.

26. Install the LH valve cover. For additional information, refer to Valve Cover - LH in this
section.
27. Install the RH valve cover. For additional information, refer to Valve Cover - RH in this
section.
28. Fill the crankcase with clean engine oil.
29. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure,
following the on-screen instructions.
Timing Drive Components
Special Tool(s)
Compressor, Valve Spring

303-1039
Holding Tool, Crankshaft

303-448 (T93P-6303-A)
Locking Tool, Cam Phaser

303-1046
General Equipment
Hydraulic Chain Tensioner Retaining Clip

1L3Z-6P250-AA
Material
Item Specification
XO-5W20-QSP (US);
Removal
1. Remove the engine front cover. For additional information, refer to Engine Front Cover in this
section.
2. Remove the crankshaft sensor ring from the crankshaft.
3. Position the crankshaft keyway at the 12 o'clock position.
Timing Drive Components 1306

4. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full
additional rotation to 12 o'clock.
The No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting
the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 1 cylinder.
5. NOTICE: If the components are to be reinstalled, they must be installed in the same positions.
Mark the components for installation into their original locations. Failure to follow these
instructions may result in engine damage.
Remove only the 3 camshaft roller followers shown in the illustration from the RH cylinder head.
6. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder.
If a valve drops into the cylinder, the cylinder head must be removed. For additional information,
refer to Cylinder Head in this section.
NOTE: It may be necessary to push the valve down while compressing the spring.
Using the Valve Spring Compressor, remove the 3 designated camshaft roller followers in the
previous step from the RH cylinder head.

Remove only the 3 camshaft roller followers shown in the illustration from the LH cylinder head.
Using the Valve Spring Compressor, remove the 3 designated camshaft roller followers in the
previous step from the LH cylinder head.
9. NOTICE: The crankshaft cannot be moved past the 6 o'clock position once set or engine
damage may occur.

Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
10. NOTICE: If one or both tensioner mounting bolts are loosened or removed, the
tensioner-sealing bead must be inspected for seal integrity. If cracks, tears, separation from the
tensioner body or permanent compression of the seal bead is observed, install a new tensioner
or engine damage may occur.
Remove the 2 bolts, the LH timing chain tensioner and tensioner arm.
Remove the 2 bolts, the RH timing chain tensioner and tensioner arm.
12. Remove the RH and LH timing chains and the crankshaft sprocket.
Remove the RH timing chain from the camshaft sprocket.
Remove the RH timing chain from the crankshaft sprocket.
Remove the LH timing chain from the camshaft sprocket.
Remove the LH timing chain and crankshaft sprocket.

Remove the LH and RH timing chain guides.
Remove the 4 bolts.

Remove both timing chain guides.
14. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
NOTICE: Only use hand tools to remove the camshaft phaser and sprocket assembly or damage
may occur to the camshaft or camshaft phaser and sprocket.
Using the Cam Phaser Locking Tool, remove the bolt and the RH camshaft phaser and sprocket
assembly.
Discard the camshaft phaser and sprocket bolt.

Using the Cam Phaser Locking Tool, remove the bolt and the LH camshaft phaser and sprocket
assembly.
16. NOTICE: Remove the front thrust camshaft bearing cap straight upward from the bearing
towers or the bearing cap may be damaged from side loading.
Remove the 2 bolts and the RH camshaft front bearing cap.
17. NOTICE: The camshaft bearing caps must be installed in their original locations. Record
camshaft bearing cap locations. Failure to follow these instructions may result in engine
damage.
Remove the remaining bolts in the sequence shown and remove the remaining RH camshaft bearing
caps.
18. Clean and inspect the RH camshaft bearing caps.

The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove
is free of foreign material.

19. Remove the RH camshaft.
Remove the 2 bolts and the RH camshaft front bearing cap.
damage.
Remove the remaining bolts in the sequence shown and remove the remaining LH camshaft bearing
caps.
22. Clean and inspect the LH camshaft bearing caps.


23. Remove the LH camshaft.
Mark the components for installation into the original locations. Failure to follow these
Remove all of the remaining camshaft roller followers from the cylinder heads.
Installation
1. Install the LH and RH camshafts.

Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
2. NOTE: LH shown, RH similar.
Install the LH and RH camshaft bearing caps in their original locations.
Lubricate the camshaft bearing caps with clean engine oil.

Position the 2 front camshaft bearing caps.
Position the 8 remaining camshaft bearing caps.
Install the 20 bolts loosely.
Tighten to 10 Nm (89 lb-in) in the sequence shown.
Position the camshaft phaser and sprockets and install 2 new camshaft phaser and sprocket bolts
finger-tight.

Using the Cam Phaser Locking Tool, tighten the LH and RH camshaft phaser and sprocket bolts in 2
stages.

5. Position the crankshaft with the Crankshaft Holding Tool, then remove the tool.
6. NOTICE: Timing chain procedures must be followed exactly or damage to valves and pistons
will result.
NOTICE: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks,
tears, separation from the tensioner body or permanent compression of the seal bead is
observed, install a new tensioner or engine damage may occur.
Compress the tensioner plunger, using a vise.
7. Install a retaining clip on the tensioner to hold the plunger in during installation.

8. Remove the tensioner from the vise.
9. If the copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as
timing marks.
10. Install the crankshaft sprocket, making sure the flange faces forward.
11. Install the 4 bolts and the LH and RH timing chain guides.
12. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing
mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.

13. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.
Position the timing chain on the camshaft phaser and sprocket with the timing mark positioned
between the 2 copper (marked) chain links.
14. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner
and the 2 bolts.
15. Remove the retaining clip from the LH timing chain tensioner.
16. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing
mark on the sprocket with the single copper (marked) chain link.

17. NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel.
NOTE: The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks
for the RH camshaft.
Position the RH timing chain on the camshaft phaser and sprocket. Make sure the timing mark is
positioned between the 2 copper (marked) chain links.
18. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain
tensioner and the 2 bolts.
19. Remove the retaining clip from the RH timing chain tensioner.
20. As a post-check, verify correct alignment of all timing marks.

21. Install the crankshaft sensor ring on the crankshaft.
22. NOTICE: If the components are to be reinstalled, they must be installed into their original
locations. Failure to follow this instruction may result in engine damage.
NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder.
Using the Valve Spring Compressor, install all of the camshaft roller followers.
Lubricate the camshaft roller followers with clean engine oil prior to installation.
23. Install the engine front cover. For additional information, refer to Engine Front Cover in this section.


Valve Train Components - Exploded View

1 N807834 Camshaft bearing cap bolt (10
required)
2 - Camshaft front bearing cap (part of
6049)
3 - Camshaft bearing cap (part of 6049) (4
required)
4 6250 Camshaft
5 Camshaft roller follower (12
required)
6 6518 Valve spring retainer key (24 required)
7 6514 Valve spring retainer (12 required)
8 6513 Valve spring (12 required)
9 6571 Valve seal (12 required)
10 6C501 Hydraulic lash adjuster (12 required)
11 6279 Camshaft phaser and sprocket bolt
12 - Camshaft phaser and sprocket (part of
6A257)
Valve Train Components - Exploded View 1320

Valve Train Components - Exploded View 1321

Camshaft - LH
Special Tool(s)

303-1039
Locking Tool, Timing Chain

303-1175
Material
Item Specification
XO-5W20-QSP (US);
Removal
NOTICE: The camshaft procedure must be followed exactly or damage to the valves and pistons will
result.
1. Position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the
1 o'clock position.
Loosen and back off the LH camshaft phaser and sprocket bolt one full turn.
4. Disconnect the LH Camshaft Position (CMP) sensor electrical connector.
Camshaft - LH 1322
5. Remove the bolt and the LH CMP sensor.
6. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft keyway will
require one full additional rotation to 12 o'clock.
The No. 5 cylinder camshaft lobe must be coming up on the exhaust stroke. Verify by noting
7. Remove only the 3 camshaft roller followers shown in the illustration.
8. NOTICE: The camshaft roller followers must be installed in their original locations.
Record camshaft roller follower locations. Failure to follow these instructions may result
in engine damage.
NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the
cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional
information, refer to Cylinder Head in this section.
Using the Valve Spring Compressor, remove only the 3 designated camshaft roller followers
from the previous step.
Camshaft - LH 1323
damage may occur.
Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper
spoke at the 6 o'clock position and the timing mark indentation at the 7 o'clock position.
10. NOTICE: Engine is not freewheeling. Camshaft procedure must be followed exactly or
damage to valves and pistons will result.
NOTE: The Timing Chain Locking Tool must be installed square to the timing chain and the
engine block.
NOTE: Engine front cover removed for clarity.
Install the Timing Chain Locking Tool in the LH timing chain as shown.
11. NOTICE: Do not remove the Timing Chain Locking Tool at any time during assembly.
If the Timing Chain Locking Tool is removed or out of placement, the engine front
cover must be removed and the engine must be retimed. For additional information,
refer to Timing Drive Components in this section.
NOTICE: The timing chain must be installed in its original position onto the camshaft
Camshaft - LH 1324
phaser and sprocket using the scribed marks, or damage to valves and pistons will
result.
Scribe a location mark on the timing chain and the camshaft phaser and sprocket assembly.
12. NOTICE: Remove the front thrust camshaft bearing cap straight upward from the
bearing towers or the bearing cap may be damaged from side loading.
Remove the 2 bolts and the LH camshaft front bearing cap.
13. NOTICE: The camshaft bearing caps must be installed in their original locations.
Record camshaft bearing cap locations. Failure to follow these instructions may result in
engine damage.
Remove the remaining 8 bolts in the sequence shown and remove the 4 camshaft bearing
caps.

The camshaft front thrust bearing cap contains an oil metering groove. Make sure the
groove is free of foreign material.
15. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if
mishandled or used as a lifting or leveraging device.
Camshaft - LH 1325
NOTICE: Only use hand tools to remove the camshaft phaser and sprocket bolt or
damage may occur to the camshaft or camshaft phaser and sprocket.
NOTICE: Do not remove the Timing Chain Locking Tool at any time during assembly.
Remove the bolt and the camshaft phaser and sprocket assembly from the camshaft.
Discard the bolt and washer.
16. Remove the camshaft.

17. Remove and inspect the camshaft phaser and sprocket for damage. For additional
Installation
1. NOTE: Do not allow the camshaft roller followers to move out of position when installing
the camshaft.
Lubricate the camshaft and camshaft journals with clean engine oil and install the camshaft.
result.
NOTE: If replacement of the camshaft phaser and sprocket is necessary, transfer the scribe
mark to the new camshaft phaser and sprocket.
Position the camshaft phaser and sprocket into the timing chain with the timing chain scribe
marks in alignment.
NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if
Camshaft - LH 1326
NOTICE: Only use hand tools to install the camshaft phaser and sprocket bolt or
Install the camshaft phaser and sprocket assembly onto the camshaft and install a new
camshaft phaser and sprocket bolt finger-tight.
the camshaft.
Install the 5 camshaft bearing caps in their original locations.

Position the 2 front camshaft bearing cap.
Position the remaining 8 camshaft bearing caps.
5. Tighten the bolts in the sequence shown.
6. NOTE: Engine front cover removed for clarity.
Remove the Timing Chain Locking Tool.
7. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke
Camshaft - LH 1327
at the 12 o'clock position and the timing mark indentation at the 1 o'clock position.
8. Verify correct camshaft position by noting the position of the No. 5 cylinder intake and
exhaust camshaft lobes.
9. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the
Using the Valve Spring Compressor, install the 3 originally removed camshaft roller
followers.
10. Install the CMP sensor and the bolt.

11. Connect the CMP electrical connector.
Camshaft - LH 1328
12. NOTICE: Only use hand tools to install the camshaft phaser and sprocket assembly or
Tighten the camshaft phaser and sprocket bolt in 2 stages:

13. Install the LH valve cover. For additional information, refer to Valve Cover - LH in this
section.
Camshaft - LH 1329
Camshaft - RH
Special Tool(s)

303-1039
Locking Tool, Timing Chain

303-1175
Material
Item Specification
XO-5W20-QSP (US);
Removal
result.
1 o'clock position.
Loosen and backoff the RH camshaft phaser and sprocket bolt one full turn.
>
Camshaft - RH 1330
4. Disconnect the RH Camshaft Position (CMP) sensor electrical connector.
5. Remove the bolt and the RH CMP sensor.
6. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require
one full additional rotation to 12 o'clock.
The No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by
noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 1 cylinder.
8. NOTICE: The camshaft roller followers must be installed in their original locations.
Record camshaft roller follower locations. Failure to follow these instructions may result
in engine damage.
NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the
Using the Valve Spring Compressor, remove only the 3 designated camshaft roller followers
from the previous step.
Camshaft - RH 1331
damage may occur.
Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper
spoke at the 6 o'clock position and the timing mark indentation at the 7 o'clock position.
10. NOTICE: Engine is not freewheeling. Camshaft procedure must be followed exactly or
damage to valves and pistons will result.
NOTE: The Timing Chain Locking Tool must be installed square to the timing chain and the
engine block.
Install the Timing Chain Locking Tool in the RH timing chain as shown.
result.
Camshaft - RH 1332
12. NOTICE: Remove the front thrust camshaft bearing cap straight upward from the
bearing towers or the bearing cap may be damaged from side loading.
Remove the 2 bolts and the front camshaft bearing cap.
13. NOTICE: The camshaft bearing caps must be installed in their original locations.
Record camshaft bearing cap locations. Failure to follow these instructions may result in
engine damage.
Remove the remaining bolts in the sequence shown and remove the remaining camshaft
bearing caps.

The camshaft front thrust bearing cap contains an oil metering groove. Make sure the
groove is free of foreign material.
15. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if
NOTICE: Only use hand tools to remove the camshaft phaser and sprocket bolt or
NOTICE: Do not remove the Timing Chain Locking Tool at any time during assembly.
Camshaft - RH 1333

17. Remove and inspect the camshaft phaser and sprocket for damage. For additional
Installation
the camshaft.
Lubricate the camshaft and camshaft journals with clean engine oil and install the camshaft.
result.
NOTE: If replacement of the camshaft phaser and sprocket is necessary, transfer the scribe
mark to the new camshaft phaser and sprocket.
Position the camshaft phaser and sprocket into the timing chain with the timing chain scribe
marks in alignment.
NOTICE: Only use hand tools to install the camshaft phaser and sprocket bolt or
Install the camshaft phaser and sprocket assembly onto the camshaft and install a new
Camshaft - RH 1334
camshaft phaser and sprocket bolt finger-tight.
the camshaft.
Install the 5 camshaft bearing caps in their original locations.

Position the front camshaft bearing cap.
Position the remaining camshaft bearing caps.
5. Tighten the 10 bolts in the sequence shown.
7. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke
at the 12 o'clock position and the timing mark indentation at the 1 o'clock position.
Camshaft - RH 1335
8. Verify correct camshaft position by noting the position of the No. 1 cylinder intake and
exhaust camshaft lobes.
9. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the
Using the Valve Spring Compressor, install the 3 originally removed camshaft roller
followers.
10. Install the CMP sensor and the bolt.

12. NOTICE: Only use hand tools to install the camshaft phaser and sprocket assembly or
Tighten the new camshaft phaser and sprocket bolt in 2 stages:
Camshaft - RH 1336
13. Install the RH valve cover. For additional information, refer to Valve Cover - RH in this
section.
Camshaft - RH 1337
Camshaft Phaser and Sprocket - LH
Special Tool(s)

303-1039
303-1175
Material
Item Specification
XO-5W20-QSP (US);
Removal
result.
1 o'clock position.
Loosen and back off the LH camshaft phaser and sprocket bolt one full turn.
4. Disconnect the LH Camshaft Poon (CMP) sensor electrical connector.
Camshaft Phaser and Sprocket - LH 1338

5. Remove the bolt and the LH CMP sensor.
6. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft keyway will require
one full additional rotation to 12 o'clock.
The No. 5 cylinder camshaft lobe must be coming up on the exhaust stroke. Verify by noting the
position of the 2 intake camshaft lobes and the exhaust lobe on the No. 5 cylinder.
8. NOTICE: The camshaft roller followers must be installed in their original locations. Record
camshaft roller follower locations. Failure to follow these instructions may result in engine
damage.

Using the Valve Spring Compressor, remove only the 3 designated camshaft roller followers from the
previous step.
damage may occur.
Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper spoke at
the 6 o'clock position and the timing mark indentation at the 7 o'clock position.
10. NOTICE: Engine is not freewheeling. Camshaft procedure must be followed exactly or damage
to valves and pistons will result.
NOTICE: The Timing Chain Locking Tool must be installed square to the timing chain and the
engine block or damage may result.
Install the Timing Chain Locking Tool in the LH timing chain as shown.

11. NOTICE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the
Timing Chain Locking Tool is removed or out of placement, the engine front cover must be
removed and the engine must be retimed. For additional information, refer to Timing Drive
Components in this section.
NOTICE: The timing chain must be installed in its original position onto the camshaft phaser
and sprocket using the scribed marks, or damage to valves and pistons will result.
NOTICE: Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may
occur to the camshaft or camshaft phaser and sprocket.
NOTICE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the

13. Remove the camshaft phaser and sprocket assembly from the timing chain and inspect for damage.
Installation
NOTE: If replacement of the camshaft phaser and sprocket is necessary, transfer the scribe mark to
the new camshaft phaser and sprocket.
Position the camshaft phaser and sprocket into the timing chain with the timing chain scribe marks in
alignment.
NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
NOTICE: Only use hand tools to install the camshaft phaser and sprocket bolt or damage may
Install the camshaft phaser and sprocket assembly onto the camshaft and install a new camshaft
phaser and sprocket bolt finger-tight.

4. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke at the 12
o'clock position and the timing mark indentation at the 1 o'clock position.
5. Verify correct camshaft position by noting the position of the No. 5 cylinder intake and exhaust
camshaft lobes.
Using the Valve Spring Compressor, install the 3 originally removed camshaft roller followers.

7. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
Install the CMP sensor and the bolt.
9. NOTICE: Only use hand tools to install the camshaft phaser and sprocket assembly or damage
Tighten the camshaft phaser and sprocket bolt in 2 stages:


10. Install the LH valve cover. For additional information, refer to Valve Cover - LH in this section.

Camshaft Phaser and Sprocket - RH
Special Tool(s)

303-1039
303-1175
Material
Item Specification
XO-5W20-QSP (US);
Removal
NOTICE: This procedure must be followed exactly or damage to the valves and pistons will result.
1 o'clock position.
Loosen and backoff the RH camshaft phaser and sprocket bolt one full turn.
4. Disconnect the RH Camshaft Position (Csensor electrical connector.
Camshaft Phaser and Sprocket - RH 1346

5. Remove the bolt and the RH CMP sensor.
8. NOTICE: The camshaft roller followers must be installed in their original locations. Record
camshaft roller follower locations. Failure to follow these instructions may result in engine
damage.

Using the Valve Spring Compressor, remove only the 3 designated camshaft roller followers from the
previous step.
damage may occur.
Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper spoke at
the 6 o'clock position and the timing mark indentation at the 7 o'clock position.
10. NOTICE: Engine is not freewheeling. Camshaft procedure must be followed exactly or damage
to valves and pistons will result.
NOTE: The Timing Chain Locking Tool must be installed square to the timing chain and the engine
block.
Install the Timing Chain Locking Tool in the RH timing chain as shown.

NOTICE: Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may
NOTICE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the
Remove the bolt and remove the camshaft phaser and sprocket assembly from camshaft.
13. Remove the camshaft phaser and sprocket assembly from the timing chain and inspect for damage.
Installation
NOTE: If replacement of the camshaft phaser and sprocket is necessary, transfer the scribe mark to
the new camshaft phaser and sprocket.
Position the camshaft phaser and sprocket into the timing chain with the timing chain scribe marks in
alignment.

NOTICE: Only use hand tools to install the camshaft phaser and sprocket bolt or damage may
Install the camshaft phaser and sprocket assembly onto the camshaft and install a new camshaft
phaser and sprocket bolt finger-tight.
4. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke at the 12
o'clock position and the timing mark indentation at the 1 o'clock position.

5. Verify correct camshaft position by noting the position of the No. 1 cylinder intake and exhaust
camshaft lobes.
Using the Valve Spring Compressor, install the 3 originally removed camshaft roller followers.
7. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
Install the CMP sensor and the bolt.

9. NOTICE: Only use hand tools to install the camshaft phaser and sprocket assembly or damage
Tighten the new camshaft phaser and sprocket bolt in 2 stages:

10. Install the RH valve cover. For additional information, refer to Valve Cover - RH in this section.

Variable Camshaft Timing (VCT) Housing
Material
Item Specification
ZC-31-A
Removal
All Variable Camshaft Timing (VCT) housings
1. Remove the timing drive components. For additional information, refer to Timing Drive Components
in this section.
RH VCT housing
2. Remove the 2 bolts and the RH Variable Camshaft Timing (VCT) housing.
LH VCT housing
3. Remove the 2 bolts and the LH VCT housing.
All VCT housings
4. Remove and discard the VCT housing gasket.

Clean and inspect the cylinder head sealing surfaces with metal surface prep. Follow the directions on
the packaging.
6. Clean and inspect the VCT housing. For additional information, refer to Section 303-00 .
Installation
All VCT housing
1. Install a new gasket onto the VCT housing.
RH VCT housing
2. Position the RH VCT housing and install the 2 bolts.

LH VCT housing
3. Position the LH VCT housing and install the 2 bolts.

All VCT housings
4. Install the timing drive components. For additional information, refer to Timing Drive Components in
this section.


Camshaft Roller Follower
Special Tool(s)

303-1039
Material
Item Specification
PrMotor Oil (Canada)
XO-5W20-QSP (US);
Removal
LH cylinder head camshaft roller followers
RH cylinder head camshaft roller followers
All camshaft roller followers
3. Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke with the
intake valve and the exhaust valves closed.
Using the Valve Spring Compressor, compress the valve spring and remove the camshaft roller
follower.
Camshaft Roller Follower 1356

5. Repeat the previous 2 steps for each camshaft roller follower being serviced.
6. Inspect the camshaft roller follower. For additional information, refer to Section 303-00 .
Installation
All camshaft roller followers
Failure to follow these instructions may result in engine damage.
NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation.
Using the Valve Spring Compressor, compress the valve spring and install the camshaft roller
follower.
2. Repeat the previous step for each camshaft roller follower being serviced.
LH cylinder head camshaft roller followers
RH cylinder head camshaft roller followers


Valve Springs
Special Tool(s)

303-1039
Material
Item Specification
Motoft SAE 5W-20 Premium WSS-M2C945-A
XO-5W20-QSP (US);
Removal
RH cylinder head valve springs
LH cylinder head valve springs
All valve springs
3. Remove the spark plug for the cylinder being serviced. For additional information, refer to Section
303-07 .
4. Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke with the
intake valve and the exhaust valves closed.
Mark the comp for installation into their original locations. Failure to follow these instructions
may result in engine damage.
follower.
Valve Springs 1359

6. Use compressed air in the cylinder being serviced to hold both valves in position.
Apply a minimum of 965 kPa (140 psi) of compressed air into the cylinder.
NOTE: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will
allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to
removal. If a valve drops into the cylinder, remove the cylinder head. For additional information, refer
to Cylinder Head in this section.
Using the Valve Spring Compressor, compress the valve spring and remove the valve spring retainer
keys.
8. Remove the valve spring retainer and the valve spring.
9. Inspect the valve spring. For additional information, refer to Section 303-00 .
Installation
All valve springs
Using the Valve Spring Compressor, install the valve spring, the valve spring retainer and the valve
spring retainer keys.
2. Relieve the air pressure from the cylinder.
Valve Springs 1360

Failure to follow this instruction may result in engine damage.
follower.
4. Install the spark plug. For additional information, refer to Section 303-07 .
LH cylinder head valve springs
RH cylinder head valve springs
Valve Springs 1361

Valve Seals
Special Tool(s)

303-1039
Installer, Valve Stem Oil Seal

303-383 (T91P-6571-A)
Material
Item Specification
XO-5W20-QSP (US);
Removal
RH cylinder head valve seals
LH cylinder head valve seals
All valve seals
3. Remove the spark plug for the cylinder being serviced. For additional information, refer to Section
303-07 .
4. Rthe crankshaft until the piston for the valve being serviced is at the top of its stroke with the intake
valve and the exhaust valves closed.
Valve Seals 1362

follower.
6. Use compressed air in the cylinder being serviced to hold the valves in position.
Apply a minimum of 965 kPa (140 psi) of compressed air into the cylinder.
NOTE: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will
allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to
removal. If a valve drops into the cylinder, remove the cylinder head. For additional information, refer
to Cylinder Head in this section.
Using the Valve Spring Compressor, compress the valve spring and remove the valve spring retainer
keys.
8. Remove the valve spring retainer, the valve spring and the valve seal.
Discard the valve seal.
9. Inspect the components. For additional information, refer to Section 303-00 .
Installation
All valve seals
1. NOTE: Lubricate the valve seal and valve stem with clean engine oil prior to installation.
Position a new valve seal onto the valve stem.
2. Using the Valve Stem Oil Seal Installer, install the new valve seal.
Valve Seals 1363

4. Relieve the air pressure from the cylinder.
follower.
6. Install the spark plug. For additional information, refer to Section 303-07 .
LH cylinder head valve seals
RH cylinder head valve seals
Valve Seals 1364

Valve Seals 1365

Hydraulic Lash Adjuster
Material
Item Specification
XO-5W20-QSP (US);
RH cylinder head hydraulic lash adjusters
1. Remove the RH camshaft. For additional information, refer to Camshaft - RH in this section.
LH cylinder head hydraulic lash adjusters
2. Remove the LH camshaft. For additional information, refer to Camshaft - LH in this section.
All hydraulic lash adjusters
3. Remove the camshaft roller follower from the hydraulic lash adjuster being serviced.
Remove the hydraulic lash adjuster that is being serviced.
5. Inspect the hydraulic lash adjuster. For additional information, refer to Section 303-00 .
6. NOTE: Lubricate the hydraulic lash adjuster with clean engine oil prior to installation.
Hydraulic Lash Adjuster 1366

Hydraulic Lash Adjuster 1367

Exhaust Manifold - RH
Material
Item Specification
ZC-31-A

1 W520514 Exhaust Y-pipe flange nuts (2
required)
2 W711460 Exhaust manifold heat shield bolt (2
required)
3 9A462 Exhaust manifold heat shield
4 W701706 haust manifold nut (8
required)
5 9430 Exhaust manifold
6 9448 Exhaust manifold gasket (2
required)
7 W707747 Exhaust manifold stud (8 required)
Removal
100-02 .
2. Remove the RH inner fenderwell. For additional information, refer to Section 501-02 .
Exhaust Manifold - RH 1368

3. Remove the RH engine support insulator. For additional information, refer to Engine Support
Insulators .
4. Remove the 2 bolts and the exhaust manifold heat shield.
5. Remove the 8 exhaust manifold nuts, the 8 studs and the exhaust manifold.
Discard the exhaust manifold nuts and studs.
means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak
paths. Use a plastic scraper to clean the sealing surfaces.
NOTE: Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging.
Remove and discard the 2 exhaust manifold gaskets. Clean the sealing surfaces with metal surface
prep.
7. Inspect the exhaust manifold. For additional information, refer to Section 303-00 .
Installation
1. Using 2 new exhaust manifold gaskets and 8 new studs, position the 2 gaskets and exhaust manifold
and install the 8 studs.
2. Using 8 new exhaust manifold nuts, install the 8 nuts.

Tighten to 25 Nm (18 lb-ft) in the sequence shown.
3. Position the exhaust manifold heat shield and install the 2 bolts.
4. Install the RH engine support insulator. For additional information, refer to Engine Support Insulators
.
5. Install the RH inner fenderwell. For additional information, refer to Section 501-02 .


Exhaust Manifold - LH
Material
Item Specification
ZC-31-A

1 W520514 Exhaust Y-pipe flange nuts (2 required)
2 W701706 Exhaust manifold nut (8 required)
3 9431 Exhaust manifold assembly
4 9Y431 Exhaust maet (2 required)
5 W707747 Exhaust manifold stud (8 required)
Removal
All vehicles
100-02 .
3. Remove the degas bottle. For additional information, refer to Section 303-03 .
disconnected or damage to the clockspring can result. If there is evidence that the shaft has
Exhaust Manifold - LH 1371

rotated, the clockspring must be removed and re-centered. For additional information, refer to
Section 501-20B .
Remove the bolt and disconnect the steering shaft and position aside.
5. Remove the 4 (2 LH and 2 RH) exhaust manifold-to-catalytic converter nuts.
Four-Wheel Drive (4WD) vehicles
6. Remove the front driveshaft. For additional information, refer to Section 205-01 .
All vehicles
7. Remove the 8 exhaust manifold nuts, the 8 studs and the exhaust manifold.
Discard the exhaust manifold nuts and studs.
NOTE: Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging.
Remove and discard the 2 exhaust manifold gaskets. Clean the sealing surfaces with metal surface
prep.
9. Inspect the exhaust manifold. For additional information, refer to Section 303-00 .
Installation
All vehicles
1. Using 2 new exhaust manifold gaskets and 8 new studs, position the 2 gaskets and exhaust manifold
and install the 8 studs.
2. Using new exhaust manifold nuts, install the 8 nuts.

Tighten to 25 Nm (18 lb-ft) in the sequence shown.

4WD vehicles
3. Install the front driveshaft. For additional information, refer to Section 205-01 .
All vehicles
disconnected or damage to the clockspring can result. If there is evidence that the shaft has
rotated, the clockspring must be removed and re-centered. For additional information, refer to
Section 501-20B .
Connect the steering shaft and install the bolt.
5. Install the 4 exhaust manifold-to-catalytic converter nuts.
6. Install the degas bottle. For additional information, refer to Section 303-03 .
7. Install the ACL outlet tube. For additional information, refer to Section 303-12 .


Engine Lubrication Components - Exploded View

1 W701605 Oil pan bolt (16 required)
2 6675 Oil pan
3 6710 Oil pan gasket
4 N806155 Oil pump screen and pickup tube-to-oil
pump bolts (2 required)
5 N605904 Oil pump screen and pickup tube support
bracket bolt
6 6622 d>Oil pump screen
and pickup tube
7 6625 Oil pump screen and pickup tube O-ring
seal
8 N806183 Oil pump bolts (3 required)
9 6621 Oil pump
Engine Lubrication Components - Exploded View 1375

Engine Lubrication Components - Exploded View 1376

Oil Pan
Material
Item Specification
ZC-31-A
(Canada)
XO-5W20-QSP (US);
TA-30
Remover
ZC-30
Removal
All vehicles
100-02 .
2. If equipped, remove the 10 bolts and the 2 skid plates.
All vehicles
3. Remove the oil drain plug and drain the engine oil. Install the drain plug when finished.
4. Remove the 4 nuts, the 4 bolts and the crossmember.
Oil Pan 1377

4WD vehicles
5. Position a suitable hydraulic jack under the front axle. Securely strap the jack to the axle.
6. NOTE: Rotate the steering column so the pinch bolt for the steering column coupling allows
clearance for the isolator bolt.
Remove the upper front axle carrier mounting bushing bolt.
7. Remove the axle shaft housing carrier bushing bolt.
8. Remove the lower front axle carrier mounting bushing bolt.
9. NOTICE: Use care when lowering the front axle housing, or the vacuum lines to the axle
solenoid may become disconnected or damaged.
Lower the axle to allow clearance for the oil pan to be removed.
Oil Pan 1378

All vehicles
10. Remove the starter wiring harness rear support bracket bolt.
11. Remove the nut and position the starter wiring harness and the transmission fluid cooler tubes aside.
12. Detach the oil pressure switch wiring harness from the oil pan bolt.
13. Remove the 16 bolts, the oil pan and the gasket.
Discard the gasket.
means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak
Inspect the oil pan. Clean the gasket mating surfaces of the oil pan and engine block with silicone
gasket remover and metal surface prep. Follow the directions on the packaging.
Installation
All vehicles
with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to
dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this
procedure can cause future oil leakage.
Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing
surface.
Oil Pan 1379

Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
3. Position a new gasket and the oil pan and install the 16 bolts.
Tighten the bolts in the sequence shown in 3 stages.
4. Attach the oil pressure switch wiring harness to the oil pan bolt.
Oil Pan 1380

5. Position the transmission fluid cooler tube support bracket, the starter wiring harness support bracket
and install the nut.
6. Position the starter wiring harness and install the starter wiring harness rear support bracket bolt.
7. Install the transmission fluid cooling tubes rear support bracket bolt.
4WD vehicles
8. NOTICE: Use care when positioning the front axle housing, or the vacuum lines to the axle
solenoid may become disconnected or damaged.
Raise the front axle carrier into position.
Oil Pan 1381

9. Install the lower front axle carrier mounting bushing bolt.
10. Install the axle shaft housing carrier bushing bolt.

11. Install the upper front axle carrier mounting bushing bolt.
All vehicles
12. Position the crossmember and install the 4 bolts and the 4 nuts.
4WD vehicles
13. If equipped, install the 2 skid plates and the 10 bolts.

All vehicles
14. Fill the engine with clean engine oil.
Oil Pan 1382

Oil Pan 1383

Oil Pump
Material
Item Specification
ZC-31-A
XO-5W20-QSP (US);
Removal
1. Remove the timing drive components. For additional information, refer to Timing Drive Components
in this section.
2. Remove the oil pan. For additional information, refer to Oil Pan in this section.
3. Remove the 3 bolts and the oil pump screen and pickup tube.
4. Remove the 3 bolts and the oil pump.
Installation
Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging. Inspect
the mating surfaces.
Oil Pump 1384

2. Position the oil pump and install the 3 bolts.
3. NOTICE: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can
cause foam in the lubrication system, low oil pressure and severe engine damage.
NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate the O-ring with
clean engine oil prior to installation.
Position the oil pump screen and pickup tube and install the 3 bolts.
Tighten the 2 oil pump screen and pickup tube-to-oil pump bolts to 10 Nm (89 lb-in).
Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft).
4. Install the oil pan. For additional information, refer to Oil Pan in this section.
5. Install the timing drive components. For additional information, refer to Timing Drive Components in
this section.
Oil Pump 1385

Oil Pump 1386

Oil Pump Screen and Pickup Tube
Material
Item Specification
XO-5W20-QSP (US);
Removal
2. Remove the 3 bolts and the oil pump screen and pickup tube.
Installation
Oil Pump Screen and Pickup Tube 1387

Oil Pump Screen and Pickup Tube 1388

Oil Filter Adapter
Material
Item Specification
ZC-31-A
XO-5W20-QSP (US);
Remover
ZC-30
Part Number Description

1 6731 Oil filter
2 14A464 Engine oil pressure switch electrical
3 8286 Lower radiator hose
4 W705128 Oil filter adapter bolt (3 required)
5 W714716 Oil filter adapter stud bolt
7 6840 Oil filter adapter gasket
100-02 .
2. Drain the engine cooling system. For additional information, refer to Section 303-03 .
Oil Filter Adapter 1389

3. Drain the engine oil.
Install the drain plug and tighten to 23 Nm (17 lb-ft).
4. Disconnect the engine oil pressure switch electrical connector.
5. Disconnect the lower radiator hose and position it aside.
6. Remove and discard the engine oil filter.

To install, lubricate the oil filter gasket with clean engine oil and tighten until the seal makes
contact.
Using an oil filter strap wrench, tighten the filter an additional 270 degrees.
7. Remove the 3 bolts, studbolt and the oil filter adapter.

Remove and discard the oil filter adapter gasket.
Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the
Inspect the mating surfaces.

Fill the engine with clean engine oil.
10. Fill and bleed the engine cooling system. For additional information, refer to Section 303-03 .
Oil Filter Adapter 1390

Engine Oil Pressure (EOP) Switch
Part
1 - Engine Oil Pressure (EOP) switch electrical connector
(part 9D930)
2 9278 EOP switch
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, ro Section 100-02 .
2. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
3. Remove the EOP switch.

Engine Oil Pressure (EOP) Switch 1391

Oil Level Indicator and Tube
Material
Item Specification
XO-5W20-QSP (US);

1 N605892 Oil level indicator and tube bolt
2 6K873 Oil level indicator and tube
3 - Oil level indicator tube O-ring seal
1. Remove the LH exhaust manifold. For additional information, refer to Exhaust Manifold - LH in this
section.
2. Remove the oil level indicator and tube bolt.

3. Remove the oil level indicator and tube from the cylinder block.
Discard the O-ring seal.
4. NOTE: Lubricate the new oil level indicator tube O-ring seal with clean engine oil prior to
installation.
Install a new O-ring seal.
Oil Level Indicator and Tube 1392

Oil Level Indicator and Tube 1393

Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View

1 N806168 Flexplate bolt (8 required)
2 6375 Flexplate tr>
3 6A373 Rear cover plate
4 6310 Crankshaft oil slinger
5 6701 Crankshaft rear seal
6 N806155 Crankshaft rear seal retainer plate bolt (6 required)
7 6K318 Crankshaft rear seal retainer plate
Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View 1394

Flexplate
1. Remove the transmission. For additional information, refer to Section 307-01 .
2. Remove the 8 bolts and the flexplate.

To install, tighten to 80 Nm (59 lb-ft) in the sequence shown.
&;
Flexplate 1395
Crankshaft Rear Seal
Special Tool(s)
Installer, Crankshaft Rear Oil Seal

303-516 (T95P-6701-BH)

303-518 (T95P-6701-DH)
Installer, Crankshaft Rear Oil Slinger

303-517 (T95P-6701-CH)
Remover, Crankshaft Rear Oil Seal

303-519 (T95P-6701-EH)
Remover, Crankshaft Rear Oil Slinger

303-514 (T95P-6701-AH)
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
XO-5W20-QSP (US);
Removal
1. Remove the transmission. For additional formation, refer to Section 307-01 .
3. Using the Slide Hammer and the Crankshaft Rear Oil Slinger Remover, remove and discard the
crankshaft oil slinger.
Crankshaft Rear Seal 1396

4. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the
crankshaft rear seal.
Installation
1. NOTE: Lubricate the crankshaft rear seal with clean engine oil prior to installation.
Using the Crankshaft Rear Oil Seal Installers, install a new crankshaft rear seal.
2. NOTE: Lubricate the crankshaft oil slinger with clean engine oil prior to installation.
Using the Crankshaft Rear Oil Seal Installers and the Crankshaft Rear Oil Slinger Installer, install a
new crankshaft oil slinger.
3. Install the flexplate and tighten the 8 bolts in the sequence shown.

4. Install the transmission. For additional information, refer to Section 307-01 .

Crankshaft Rear Seal with Retainer Plate
Special Tool(s)

303-516 (T95P-6701-BH)

303-518 (T95P-6701-DH)

303-517 (T95P-6701-CH)

303-519 (T95P-6701-EH)

303-514 (T95P-6701-AH)
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
ZC-31-A
(Canada)
XO-5W20-QSP (US);
CXO-5W20-LSP12 (Ca
TA-30
Remover
ZC-30
Removal
1. Remove the transmission. For additional information, refer to Section 307-01 .
Crankshaft Rear Seal with Retainer Plate 1399

3. Remove the rear engine cover.
6. Remove the 6 bolts and the crankshaft rear seal retainer plate.
Installation
NOTE: Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the
Clean and inspect the mating surface.
2. NOTE: If the rear crankshaft seal retaining plate is not secured within 4 minutes, the sealant must be
removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the
directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is
longer. Failure to follow this procedure may cause future oil leaks.
NOTE: The silicone must be applied on the groove along the retainer plate.
Apply a 4.06 mm (0.16 in) bead of silicone gasket and sealant around the crankshaft rear seal retainer
plate sealing surface.
3. Install the crankshaft rear seal retainer plate and the 6 bolts in the sequence shown.

4. NOTE: Lubricate the crankshaft rear seal with clean engine oil prior to installation.
Using the Crankshaft Rear Oil Seal Installers, install a new crankshaft rear seal.
5. NOTE: Lubricate the crankshaft oil slinger with clean engine oil prior to installation.
Using the Crankshaft Rear Oil Seal Installers and the Crankshaft Rear Oil Slinger Installer, install a
new crankshaft oil slinger.
6. Install the rear engine cover.
7. Install the flexplate and tighten the 8 bolts in the sequence shown.

9. Install the transmission. For additional information, refer to Section 307-01 .

Engine Support Insulators
Special Tool(s)
Support Bar, Engine

303-F070
Support Bracket, Engine

303-639
Support Hook
303-F071
Material
Item Specification
TA-26
LH Engine Support Insulator
Part
1 W712805 LH engine support insulator-to-frame bolt (3 required)
Engine Support Insulators 1403

2 W711142 LH engine support insulator through bolt

3 6B032 LH engine support insulator
4 W711141 LH engine support insulator-to-cylinder block bracket
bolt (3 required)
5 6061 LH engine support insulator-to-cylinder block bracket
RH Engine Support Insulator
Part
1 W707251 RH engine support insulator-to-frame nut (2 required)
2 W711144 RH engine support insulator-to-frame stud bolt (2
required)
3 W711142 RH engine support insulator through bolt
4 6H028 RH engine support insulator
5 W711141 RH engine support insulator-to-cylinder block bracket
bolt (3 required)
6 - RH engine support insulator-to-cylinder block bracket
Removal
All engine support insulators
100-02 .
2. Disconnect the battery ground cable. For additional information, refer to Section 414-01 .
3. Remove the Throttle Body (TB). For additional information, refer to Section 303-04 .
LH Engine Support Insulator 1404

4. Remove the cooling fan. For additional information, refer to Section 303-03 .
5. Remove the generator. For additional information, refer to Section 414-00 .
6. Remove the starter. For additional information, refer to Section 303-06 .
7. If servicing the engine support insulators on a Four-Wheel Drive (4WD) vehicle, remove the front
driveshaft. For additional information, refer to Section 205-01 .
8. Install the Engine Support Bar, Support Hook and Engine Support Bracket.
9. Remove the 4 (2 RH and 2 LH) Y-pipe flange nuts.
10. NOTICE: Only use hand tools when removing the transmission mount-to-crossmember nuts or
damage to the transmission mount can occur.
Loosen the 2 transmission mount-to-crossmember nuts.
RH engine support insulator
11. NOTICE: Only use hand tools when loosening the engine support insulator through bolts or
damage to the engine support insulator-to-cylinder block bracket can occur.
Loosen the LH engine support insulator through bolt.
12. NOTICE: Only use hand tools when removing the engine support insulator through bolts or
Remove the RH engine support insulator through bolt.
13. NOTICE: Only use hand tools when removing the engine support insulator nuts or damage to
the engine support insulator can occur.
RH Engine Support Insulator 1405

NOTE: If during nut removal the stud bolt is extracted from the engine support insulator, separate the
nut from the stud bolt prior to stud bolt installation.
Remove the 2 RH engine support insulator nuts.
14. NOTICE: Only use hand tools when removing the engine support insulator stud bolts or
damage to the engine support insulator can occur.
Remove the 2 RH engine support insulator stud bolts.
15. Using the Engine Support Bar, Support Hook and Engine Support Bracket, raise the engine.
16. Remove the 3 bolts and the RH engine support insulator-to-cylinder block bracket.
17. Remove the RH engine support insulator.
LH engine support insulator
18. NOTICE: Only use hand tools when loosening the engine support insulator through bolts or
Loosen the RH engine support insulator through bolt.
19. NOTICE: Only use hand tools when removing the engine support insulator through bolts or
Remove the LH engine support insulator through bolt.
20. Using the Engine Support Bar, Support Hook and Engine Support Bracket, raise the engine.
21. NOTICE: Only use hand tools when removing the engine support insulator-to-frame bolts or
damage to the engine support insulator-to-frame nut plate can occur.
Remove the 3 engine support insulator-to-frame bolts.
Discard the 3 bolts.
22. Remove the 3 bolts and the LH engine support insulator-to-cylinder block bracket.

23. Remove the LH engine support insulator.
24. Inspect the engine support insulator-to-frame nut plate for thread damage. If the nut plate is damaged,
bend 2 tabs back and remove the nut plate. Replace the nut plate with service part No. 56190 and
bend the 2 tabs back to the original position.
Installation
RH engine support insulator
1. Clean the engine support insulator-to-cylinder block and engine support insulator-to-frame mating
surfaces of any dirt or foreign material prior to installation.
2. NOTICE: Only use hand tools when installing the engine support insulator stud bolts or damage
to the engine support insulator can occur.
Position the RH engine support insulator into the vehicle and install the 2 stud bolts.
3. Position the RH engine support insulator-to-cylinder block bracket and install the 3 bolts.
4. NOTICE: Only use hand tools when installing the RH engine support insulator nuts or damage
to the engine support insulator can occur.
Install the 2 RH engine support insulator nuts.
LH engine support insulator
5. Clean the engine support insulator-to-cylinder block and engine support insulator-to-frame mating
surfaces of any dirt or foreign material prior to installation.
6. Position the LH engine support insulator and hand start the 3 new engine support insulator-to-frame
bolts.
7. Position the LH engine support insulator-to-cylinder block bracket and install the 3 bolts.

All engine support insulator
8. Using the Engine Support Bar, Support Hook and Engine Support Bracket, lower the engine into
position.
9. NOTICE: Only use hand tools when installing the engine support insulator through bolt or
Install the LH and RH engine support insulator bolts.
Apply threadlock to the bolt threads prior to installation.

10. NOTICE: Only use hand tools when installing the transmission mount-to-crossmember nuts or
damage to the transmission mount can occur.
Install the transmission mount-to-crossmember nuts.
11. Position the Y-pipe and install the 4 (2 RH and 2 LH) nuts.
12. Remove the Engine Support Bar, Support Hook and Engine Support Bracket.

13. Install the starter. For additional information, refer to Section 303-06 .
14. If servicing the engine support insulator on a 4WD vehicle, install the front driveshaft. For additional
15. Install the generator. For additional information, refer to Section 414-00 .
16. Install the cooling fan. For additional information, refer to Section 303-03 .
17. Install the TB . For additional information, refer to Section 303-04 .

REMOVAL Procedure revision date: 08/12/2010
Engine
Special Tool(s)
Lifting Bracket, Engine

303-F047 (014-00073) or equivalent
Remover, Power Steering Pump Pulley

211-016 (T69L-10300-B)
100-02 .
2. NOTE: Index-mark the hood hinge location to aid in hood installation.
Remove the 4 bolts and the hood.
damage.
Remove the intake manifold. For additional information, refer to Intake Manifold in this section.
4. Remove the accessory drive belt.
5. Remove the cooling module. For additional information, refer to Section 303-03 .
6. Position the Power Distribution Box (PDB) and wiring harness forward.
7. Remove the starter. For additional information, refer to Section 303-06 .
8. Remove the 2 bolts and the flexplate inspection cover.
Engine 1410
9. Remove the cylinder block opening cover.
10. Remove the 4 torque converter-to-flexplate nuts.

Discard the nuts.
11. NOTE: The upper 2 transmission-to-engine bolts will be removed later.
Remove the lower 5 transmission-to-engine bolts.
12. Remove the drain plug and drain the engine oil. Install the drain plug when finished.
13. Disconnect the A/C compressor electrical connector and the wiring harness retainer.
Engine 1411
15. Remove the bolts and position the A/C compressor aside.
16. Remove the bolt and position aside the starter wiring harness and rear support bracket.
17. If equipped, disconnect the block heater electrical connector.
18. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and detach the wiring harness
retainers from the oil pan bolt, the power steering pump stud bolt and the engine block.
Engine 1412
19. Remove the 4 exhaust Y-pipe flange nuts.
20. NOTICE: Only use hand tools when removing the engine support insulator nuts or the engine
support insulator may be damaged.
NOTE: If during nut removal the stud bolt is extracted from the engine support insulator, separate the
nut from the stud bolt prior to stud bolt installation.
Remove the 2 RH engine support insulator nuts.
21. NOTICE: Only use hand tools when loosening the engine support insulator through bolt or the
engine support insulator may be damaged.
Remove the LH engine support insulator bolt.
22. Loosen the 2 transmission mount nuts.
Engine 1413
23. Remove the nut and position aside the transmission cooler tube support bracket and the starter wiring
harness support bracket.
24. Remove the Power Steering Pressure (PSP) tube support bracket nut.
25. NOTICE: While servicing the power steering system, care should be taken to prevent the entry
of foreign material or failure of the power steering components may result.
Remove the bolt and detach the power steering fluid tubes from the steering gear.
26. NOTICE: Do not install a power steering pump pulley that has been removed and installed
twice or pulley failure and/or pump damage may occur. Inspect the pulley for paint marks in
the web area near the hub. If there are 2 paint marks, discard the pulley and install a new one.
If there is one paint mark or no paint marks, use a paint pencil to mark the web area of the
pulley near the hub.
Using the Power Steering Pump Pulley Remover, remove the power steering pump pulley.
27. Remove the 2 bolts, 1 stud bolt and position aside the power steering pump and reservoir as an
assembly.
Engine 1414
28. Disconnect electrical connector and detach the connector and wiring harness retainers.
29. Disconnect the PCM electrical connector and the engine wiring harness retainer and position the
engine wiring harness aside.
30. Remove the ground strap bolt.
31. Disconnect the RH Knock Sensor (KS) electrical connector and the heater coolant hose.
32. Disconnect the LH KS electrical connector.
Engine 1415
33. Disconnect the Cylinder Head Temperature (CHT) electrical connector.
34. Disconnect the RH Camshaft Position (CMP) sensor electrical connector and the 2 wiring harness
retainers.
35. Disconnect the RH Variable Camshaft Timing (VCT) solenoid and the RH radio ignition interference
capacitor electrical connectors.
36. Disconnect the 4 RH ignition coil electrical connectors and the 2 engine wiring harness retainers from
the RH valve cover studs.
37. Disconnect the LH CMP sensor, radio interference capacitor and VCT solenoid electrical connectors
and detach the radio interference capacitor electrical connector retainer and the 2 wiring harness
retainers.
Engine 1416
38. Disconnect the transmission wiring harness retainer from the intake manifold vacuum tube support
bracket.
39. Position the engine wiring harness aside.
40. Support the transmission.
41. NOTE: On 4WD vehicles, it may be necessary to reposition the transfer case vent hose to access the
bolts.
Remove the upper 2 transmission-to-engine bolts.
42. Install the Engine Lifting Bracket.
43. Using a suitable floor crane, remove the engine assembly from the vehicle.
Engine 1417
Engine 1418
Cylinder Head
Special Tool(s)
3 Jaw Puller

303-1039

303-F047 (014-00073) or equivalent

303-1046

303-107 (T74P-6700-A)
Remover/Installer, Cylinder Head

303-572 (T97T-6000-A)
Material
Item Specification
ZC-31-A
ZC-30
All cylinder heads
1. Remove the engine. For additional information, refer to Engine in this section.
2. NOTICE: Do not use the oil pan to support the engine or oil pan and oil pan gasket damage may
occur.
Lower and support the engine assembly on wood blocks.
3. Remove the Engine Lifting Bracket.
Cylinder Head 1419

4. Install the engine onto an engine stand.
5. If equipped with cylinder block drain plugs, remove the 3 bolts and the RH engine support insulator.
If equipped, remove the cylinder block drain plugs and drain the coolant into a suitable container.
If equipped, install the cylinder block drain plugs.
8. Remove the nut and the RH radio interference capacitor.
9. Remove the nut and the LH radio ignition interference capacitor.
Cylinder Head 1420

10. Remove the bolt and the intake manifold vacuum tube support bracket.
Remove the 8 bolts and the 8 ignition coils.
Remove the ignition coil using a twisting motion while pulling up on the ignition coil.
12. Remove the bolt and the oil level indicator tube.
NOTICE: Remove the valve cover carefully, or the Variable Camshaft Timing (VCT) solenoid
may be damaged.
NOTE: The bolts are part of the valve cover and should not be removed.
Loosen the 9 bolts and remove the LH valve cover.
Cylinder Head 1421

Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean
the valve cover gasket groove with soap and water or a suitable solvent.
may be damaged.
Loosen the 8 bolts and remove the RH valve cover.
15. Remove the 7 bolts, the coolant pump pulley and the 3 accessory drive belt idler pulleys.
17. Remove and discard the crankshaft pulley bolt. Using the 3 Jaw Puller, remove the crankshaft pulley.
Cylinder Head 1422

19. Remove the front 4 oil pan bolts.
20. NOTE: Correct fastener location is essential for the assembly procedure. Record fastener location.
Remove the 15 engine front cover fasteners.
21. Remove the engine front cover from the cylinder block.
Cylinder Head 1423

26. NOTICE: Do not allow the valve keepers to fall off the valve or the valve may drop into the
cylinder. If the valve drops into the cylinder, the cylinder head must be removed.
Cylinder Head 1424

Using the Valve Spring Compressor, remove the 3 roller followers designated in the previous step
from the RH cylinder head.
28. NOTICE: Do not allow the valve keepers to fall off the valve or the valve may drop into the
cylinder. If the valve drops into the cylinder, the cylinder head must be removed.
Using the Valve Spring Compressor, remove the 3 roller followers designated in the previous step
from the LH cylinder head.
Cylinder Head 1425

29. NOTICE: The crankshaft cannot be moved past the 6 o'clock position once set. Failure to follow
these instructions may result in engine damage.
30. Remove the 2 bolts, the LH timing chain tensioner and tensioner arm.
31. Remove the 2 bolts, the RH timing chain tensioner and tensioner arm.
Cylinder Head 1426

Remove the 4 bolts.

LH cylinder head
34. NOTICE: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as
a lifting or leveraging device.
NOTICE: Only use hand tools to remove the camshaft phaser sprocket assembly or damage
may occur to the camshaft or camshaft phaser unit.
NOTICE: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as
a lifting or leveraging device.
Using the Cam Phaser Locking Tool, remove the bolt and the LH camshaft phaser sprocket assembly.
Discard the camshaft phaser sprocket bolt.
35. Inspect the camshaft phaser sprocket. For additional information, refer to Section 303-00 .
Cylinder Head 1427

towers, or the bearing cap may be damaged from side loading.
Remove the 2 bolts and the LH cylinder head camshaft front bearing cap.
damage.
Remove the remaining 8 bolts in the sequence shown and remove the LH cylinder head camshaft
bearing caps.

Remove all of the remaining camshaft roller followers from the cylinder head.
Cylinder Head 1428

Remove the hydraulic lash adjusters from the LH cylinder head.
42. Install the Cylinder Head Remover/Installer on the LH cylinder head.
43. Remove the 8 nuts and the LH exhaust manifold.

Discard the 8 nuts.
Discard the 2 gasket.
Inspect the exhaust manifold. For additional information, refer to Section 303-00 .
44. Remove and discard the 8 LH exhaust manifold-to-cylinder head studs.
RH cylinder head
assembly.
Discard the camshaft phaser sprocket bolt.
Cylinder Head 1429

46. Inspect the camshaft phaser sprocket. For additional information, refer to Section 303-00 .
Remove the 2 bolts and the RH cylinder head camshaft front bearing cap.
damage.
Remove the remaining 8 bolts in the sequence shown and remove the RH cylinder head camshaft
bearing caps.

Cylinder Head 1430

Remove all of the remaining camshaft roller followers from the cylinder head.
Remove the hydraulic lash adjusters from the RH cylinder head.
53. Install the Cylinder Head Remover/Installer on the RH cylinder head.
54. Remove the 8 nuts and the RH exhaust manifold.

Discard the 8 nuts.
Discard the 2 gaskets.
55. Remove and discard the 8 RH exhaust manifold-to-cylinder head studs.
56. Remove the nut and the ground strap.
Cylinder Head 1431

57. Remove the stud bolt and the coolant tube.
Discard the O-ring seals.
All cylinder heads
58. NOTICE: The cylinder head must be cool before removing it from the engine. Cylinder head
warpage may result if a warm or hot cylinder head is removed.
NOTICE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so
foreign material is not dropped into the engine.
NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These tools cause scratches and gouges that make leak
paths. Use a plastic scraping tool to remove all traces of the head gasket.
NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder
head gasket surface, unprotected, on a bench surface, or the cylinder head may be damaged.
NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are a
tighten-to-yield design and cannot be reused.
Remove the 20 bolts and the cylinder heads.
Discard the cylinder head gaskets.

Discard the cylinder head bolts.
means to clean the sealing surfaces. These tools cause scratches and gouges that make leak
paths. Use a plastic scraping tool to remove all traces of the head gasket.
Cylinder Head 1432

NOTE: Observe all warnings or notices and follow all application directions contained on the
packaging of the silicone gasket remover and the metal surface prep.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and
prepare the surfaces.
Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder
block in the following sequence.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply silicone gasket remover, following package directions and allow to set for several
minutes.
3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone
gasket remover may be required if residual traces of silicone or gasket material remain.
4. Apply metal surface prep, following package directions, to remove any remaining traces of
oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to
make the metal shiny. Some staining of the metal surfaces is normal.
Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head
distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area.
Cylinder Head 1433

Cylinder Head 1434

DISASSEMBLY Procedure revision date: 08/12/2010
Engine
Special Tool(s)
3 Jaw Puller
303-D121

303-1039
Installer, Connecting Rod

303-442 (T93P-6136-A)

303-F047 (014-00073) or equivalent

303-1046

303-107 (T74P-6700-A)

303-519 (T95P-6701-DH)

303-514 (T95P-6701-AH)

303-572 (T97T-6000-A)
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
ZC-31-A
ZC-30
NOTICE: Remove the cylinder heads before removing the crankshaft. Failure to do so may result in
engine damage.
Engine 1435
NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material,
including any material created while cleaning gasket surfaces that enters the oil passages, coolant
passages or the oil pan, may cause engine failure.
NOTE: The flexplate or flywheel, crankshaft rear seal and the crankshaft rear oil slinger must be removed
before mounting the engine on the engine stand.
NOTE: For addi information, refer to the exploded view under the Assembly procedure in this section.
4. Remove the 8 bolts and the crankshaft rear seal retainer plate.
NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other
abrasive means to clean the sealing surfaces. These tools cause scratches and gouges,
Clean and inspect the sealing surfaces.
Engine 1436
5. Mount the engine on an engine stand.
7. Remove the 3 bolts and the RH engine support insulator.
If equipped, remove the cylinder block drain plugs and drain the coolant into a suitable container.
If equipped, install the cylinder block drain plugs.
10. Remove the nut and the RH radio interference capacitor.
Engine 1437
11. Remove the nut and the LH radio ignition interference capacitor.
12. Remove the bolt and the intake manifold vacuum tube support bracket.
Remove the 8 bolts and the 8 ignition coils.
Remove the ignition coil using a twisting motion while pulling up on the ignition coil.
14. Remove the 2 bolts and both of the Knock Sensor (KS).
15. Remove the stud bolt and the coolant tube.

16. Remove the 3 bolts and the LH engine support insulator-to-cylinder block bracket.
Engine 1438
17. Remove the bolt and the oil level indicator tube.
may be damaged.
Loosen the 9 bolts and remove the LH valve cover.
may be damaged.
Loosen the 8 bolts and remove the RH valve cover.
Engine 1439
20. Remove the 8 nuts, the 8 studs and the LH exhaust manifold.
Discard the gaskets, nuts and studs.
21. Remove the 8 nuts, the 8 studs and the RH exhaust manifold.
Discard the gaskets, nuts and studs.
22. Remove and discard the oil filter. Remove the 3 bolts, the studbolt and the oil filter adapter.
23. Remove the 7 bolts, coolant pump pulley and the 3 accessory drive belt idler pulleys.
Engine 1440
26. Remove the coolant pump from the cylinder block.

27. Remove and discard the crankshaft pulley bolt. Using the 3 Jaw Puller, remove the crankshaft pulley.
Engine 1441
29. Remove the 16 bolts, oil pan and oil pan gasket.
NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other
abrasive means to clean the sealing surfaces. These tools cause scratches and gouges,
Clean and inspect the sealing surfaces.
30. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
Remove the 10 bolts and the 5 studs.
31. Remove the engine front cover from the cylinder block.
Engine 1442
If a valve drops into the cylinder, the cylinder head must be removed.
Using the Valve Spring Compressor, remove the 3 camshaft roller followers designated in the
previous step from the RH cylinder head.
Engine 1443
Using the Valve Spring Compressor, remove the 3 camshaft roller followers designated in the
previous step from the LH cylinder head.
damage may occur.
Engine 1444
Remove the 2 bolts, the LH timing chain tensioner and tensioner arm.
Remove the 2 bolts, the RH timing chain tensioner and tensioner arm.
Engine 1445
Remove the 4 bolts.

assembly.
Engine 1446
Using the Cam Phaser Locking Tool, remove the bolt and the LH camshaft phaser and sprocket
assembly.
46. Install the Cylinder Head Remover/Installer onto the LH cylinder head.
47. Install the Cylinder Head Remover/Installer onto the RH cylinder head.
Remove the 2 bolts and the RH cylinder head camshaft front bearing cap.
damage.
Remove the remaining 8 bolts in the sequence shown and remove the RH cylinder head camshaft
bearing caps.
Engine 1447

Remove the remaining camshaft roller followers from the RH cylinder head.
Remove the hydraulic lash adjusters from the RH cylinder head.
Remove the 2 bolts and the LH cylinder head camshaft front bearing cap.
Engine 1448
damage.
Remove the remaining 8 bolts in the sequence shown and remove the LH cylinder head camshaft
bearing caps.

Mark the components for installation into the original locations. Failure to follow these
Remove the remaining camshaft roller followers from the LH cylinder head.
Remove the hydraulic lash adjusters from the LH cylinder head.
60. NOTICE: The cylinder head must be cool before removing it from the engine. Cylinder head
warpage may result if a warm or hot cylinder head is removed.
NOTICE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so
foreign material is not dropped into the engine. Failure to follow this procedure may cause
engine damage.
NOTICE: The cylinder head bolts must be discarded and new bolts must be installed. They are
a tighten-to-yield design and cannot be reused.
Engine 1449
NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder
head gasket surface, unprotected, on a bench surface. Failure to follow this procedure may
cause engine damage.
Remove the bolts and the cylinder head.
Discard the cylinder head gasket.

Discard the cylinder head bolts.
NOTICE: Observe all warnings or notices and follow all application directions contained on the
packaging of the silicone gasket remover and the metal surface prep. Failure to follow this
procedure may cause engine damage.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and
prepare the surfaces.
Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder
block in the following sequence.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply silicone gasket remover, following package directions, and allow to set for several
minutes.
3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone
gasket remover may be required if residual traces of silicone or gasket material remain.
4. Apply metal surface prep, following package directions, to remove any remaining traces of
oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to
make the metal shiny. Some staining of the metal surfaces is normal.
Engine 1450
Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head
distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area.
63. Remove the 3 bolts, the oil pump screen and pickup tube and the spacer.
64. Remove the 3 bolts and the oil pump.
65. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or
carbon deposits from each cylinder using an abrasive pad or equivalent, following the manufacturer
instructions.
66. NOTICE: Verify that the connecting rods and rod caps have orientation numbers cast into
them. If not, number the connecting rods and rod caps for correct orientation. Failure to follow
these instructions may result in engine damage.
Remove the 16 bolts and the 8 connecting rod caps. Discard the bolts.
Engine 1451
67. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Use the Connecting Rod Installer to push the piston through the top of the cylinder block.
68. Disassemble the 8 pistons. For additional information, refer to Piston in this section.
69. Remove the fasteners.

1. Remove and discard the 10 cross-mounted main cap bolts.
2. Remove the 10 dowels.
3. Remove and discard the 10 main bearing cap bolts.
Engine 1452
70. Remove the main bearing caps, the lower crankshaft main bearings and the lower thrust washer.
71. Remove the crankshaft, the upper crankshaft main bearings and the upper thrust washers from the
cylinder block.
Engine 1453

SECTION 303-01: Engine - 5.4L (3V)
Manual
DISASSEMBLY AND ASSEMBLY OF
Procedure revision date: 08/12/2010
SUBASSEMBLIES
Cylinder Head
Special Tool(s)

303-1039

303-383 (T91T-6571-A)
Material
Item Specification
XO-5W20-QSP (US);
Part
1 W701520 Variable Camshaft Timing (VCT) housing assembly
bolts (2 required)
Cylinder Head 1454

2 6C261 VCT housing assembly - LH

3 N807834 Camshaft bearing cap bolt (10 required)
4 - Camshaft front bearing cap (part of 6049)
5 - Camshaft bearing cap (part of 6049) (4 required)
6 6250 Camshaft
7 6518 Valve spring retainer key (24 required)
8 6514 Valve spring retainer (12 required)
10 6571 Valve seal (12 required)
11 6507 Intake val required)
12 6505 Exhaust valve (4 required)
13 6049 Cylinder head
Disassembly
1. Remove the 2 bolts and the Variable Camshaft Timing (VCT) housing.
Discard the gasket.
2. Lubricate the camshaft and camshaft journals with clean engine oil and install the camshaft.
3. Install the camshaft bearing caps in their original locations.

Install the 10 bolts finger-tight.
4. Using the Valve Spring Compressor, compress the valve spring and remove the valve spring retainer
keys.
5. Remove the valve spring retainer, the valve spring and the valve seal.
Discard the valve seal.
6. Remove the valve from the cylinder head.
7. Repeat the previous 3 steps for each valve.
8. Inspect the components. For additional information, refer to Section 303-00 .
Remove the 10 bolts, the front camshaft bearing cap and then the remaining bearing caps.
Cylinder Head 1455

11. Check the cylinder head for distortion. For additional information, refer to Section 303-00 .
Assembly
1. Lubricate the camshaft and camshaft journals with clean engine oil and install the camshaft.
2. Install the camshaft bearing caps in their original locations.

Install the 10 bolts finger-tight.
3. NOTE: Lubricate the valve stem with clean engine oil prior to installation.
Install the valve into the cylinder head.
4. NOTE: Lubricate the valve seal and valve stem with clean engine oil prior to installation.
Position a new valve seal onto the valve stem.
5. Using the Valve Stem Oil Seal Installer, install the new valve seal.
6. NOTICE: If the components are to be reinstalled, they must be installed into their original
locations. Failure to follow these instructions may result in engine damage.
7. Repeat the previous 2 steps for each valve.
8. Remove the 8 bolts, the front camshaft bearing cap and then the remaining bearing caps.
10. Install a new gasket, the VCT housing and the 2 bolts.
Cylinder Head 1456

Cylinder Head 1457


Manual
SUBASSEMBLIES
Piston
Material
Item Specification
XO-5W20-QSP (US);

1 6150 Piston compression upper ring
2 6152 Piston compression lower ring
3 6159 Piston oil control upper segment ring
4 6161 Piston oil control spacer
5 6159 Piston oil control lower segment ring
6 6140 Piston pin retainer
7 6140 Piston pin retainer
8 6135 Piston pin
9 6200 Connecting rod
10 - Connecting rod bearing cap (part of 6200)
11 6414 Connecting rod bearing cap bolt (2 required)
12 6110 Piston
Disassembly
WARNING: Since the retainer ring has a tendency to spring out, cover the end of the pin bore with
a hand or shop rag when removing the ring. Wear eye protection. Failure to follow these instructions
Piston 1458
1. Remove the piston rings from the piston.

Discard the piston rings.
2. Mark the piston and connecting rod on the same side for assembly reference.
3. Remove the 2 piston pin retainers and the piston pin.
4. Separate the piston from the connecting rod.
5. Clean and inspect the piston and connecting rod. For additional information, refer to Section 303-00 .
Assembly
1. NOTE: The connecting rod must be installed into the piston with the marks made during disassembly
on the same side. If a new piston or connecting rod is being installed, it can be installed in either
direction.
Position the connecting rod in the piston.
2. Lubricate the piston pin and pin bore with clean engine oil.
3. Install the piston pin in the piston and connecting rod assembly.
4. Install the 2 piston pin retaining clips in the piston.
Piston 1459
5. Lubricate the piston and the new piston rings with clean engine oil.
6. Install the piston rings onto the piston.
Piston 1460

Manual
SUBASSEMBLIES
Intake Manifold Assembly
Material
Item Specification
XO-5W20-QSP (US);
Evaporative Emission (EVAP) Purge Valve, Fuel Rail and Fuel Injectors
Part
1 W506023 Evaporative Emission (EVAP) purge valve support
bracket bolt
2 9C915 EVAP purge valve and tube assembly
3 W708650 Fuel rail bolt (4 required)
4 9F792 Fuel rail
5 9C995 Fuel injector-to-fuel rail locking clip (8 required)
6 9229 Fuel injector-to-fuel rail O-ring seal (8 required)
Intake Manifold Assembly 1461

7 9F593 Fuel injector (8 required)

8 9229 Fuel injector-to-intake manifold O-ring seal (8
required)
Intake Manifold Vacuum Tube, Throttle Body (TB) and Intake Manifold

1 W500204 PCV fitting bolt (2 required)
2 9F695 PCV fitting
3 9A474 Intake manifold vacuum tube assembly
4 W704840 Intake manifold vacuum tube assembly clamp
5 W503282 Throttle Body (TB) bolt (4 required)
6 9J444 Vibration damper
7 9E926 TB assembly
8 9E936 TB seal
9 9424 Intake manifold
Disassembly
1. Remove the bolt and disconnect the quick connect coupling and remove the Evaporative Emission
(EVAP) purge valve assembly.
2. Remove the 4 bolts and the fuel rail.
3. Remove the 8 fuel injector-to-fuel rail locking clips and separate the 8 fuel injectors from the fuel rail.
Discard the 2 O-ring seals from each fuel injector.
4. Remove the vacuum tube assembly from the intake manifold.
5. Remove the 2 bolts and the PCV fitting.
Evaporative Emission (EVAP) Purge Valve, Fuel Rail and Fuel Injectors 1462
6. Remove the 4 bolts, the vibration damper and the Throttle Body (TB).
Assembly
damage.
NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
Install the PCV fitting and the 2 bolts.
2. Install the vacuum tube assembly onto the intake manifold and position the clamp.
3. Install the TB , vibration damper and tighten the 4 bolts in 2 stages.

4. NOTE: Lubricate the new O-ring seals with clean engine oil prior to installation.
Install 16 new O-ring seals on each of the fuel injectors.
5. Assemble the 8 fuel injectors onto the fuel rail and install the 8 locking clips.
6. Install the fuel rail and fuel injector as an assembly onto the intake manifold.
7. Install the 4 fuel rail bolts.

8. Position the Evaporative Emission (EVAP) purge valve assembly and connect the quick connect
coupling and install the bolt.
Intake Manifold Vacuum Tube, Throttle Body (TB) and Intake Manifold 1463
Intake Manifold Vacuum Tube, Throttle Body (TB) and Intake Manifold 1464
ASSEMBLY Procedure revision date: 05/05/2011
Engine
Special Tool(s)
Alignment Pins, Cylinder Head

303-1040 (SR-015486)
Compressor, Piston Ring

303-D032 (D81L-6002-C) or equivalent

303-1039

303-448 (T93P-6303-A)
Installer, Connecting Rod

303-442 (T93P-6136-A)

303-635

303-516 (T95P-6701-EH)

303-518 (T95P-6701-DH)

303-517 (T95P-6701-CH)

303-102 (T74P-6316-B)

303-335 (T88T-6701-A)

303-F047 (014-00073) or equivalent

303-1046
Engine 1465

303-572 (T97T-6000-A)
General Equipment
Hydraulic Chain Tensioner Retaining Clip

1L3Z-6P250-AA
Material
Item Specification
ZC-31-A
Motorcraft Premium Gold WSS-M97B51-A1
Engine Coolant
VC-7-B (US); CVC-7-B (Canada)
(Canada)
XO-5W20-QSP (US);
Motorcraft Specialty Orange WSS-M97B44-D
Engine Coolant
Silicone Brake Caliper Grease and ESE-M1C171-A
Dielectric Compound
XG-3-A
TA-30
Remover
ZC-30
Engine - Upper End
Engine - Upper End 1466


1 9D930 Engine wiring harness
2 6582 Valve cover - LH
3 6750 Oil level indicator
4 N605892 Oil level indicator tube bolt
5 6754 Oil level indicator tube
6 N807834 Camshaft bearing cap bolt
(10 required)
7 - Camshaft bearing cap (part
of 6049) (4 required)
8 6250 Camshaft - LH
9 6564 Roller follower (24
required)
10 6518 Valve spring retainer key
(48 required)
11 6514 Valve spring retainer (24
required)
13 6571 Valve stem seal (24
required)
14 6C501 Hydraulic lash adjuster (24
required)
15 6279 Camshaft phaser and
sprocket bolt

16 - Camshaft phaser and

sprocket (part of 6A257)
Camshaft bearing
- cap (part of 6049)
18 HJFS-24FP- Spark plug (4 required)
19 12029 Ignition coil (4 required)
20 6065 Cylinder head bolt (20
required)
21 W703902 Exhaust manifold stud (8
required)
22 9448 Exhaust manifold gasket (2
required)
23 9431 Exhaust manifold - LH
24 W701706 Exhaust manifold nut (8
required)
25 6507 Intake valve (16 required)
26 6505 Exhaust valve (8 required)
27 6051 Cylinder head gasket - LH
28 W701520 Variable Camshaft Timing
(VCT) oil control solenoid
assembly bolt (2 required)
29 6C261 VCT oil control solenoid
assembly - LH
30 6049 Cylinder head - LH
31 14A411 Cylinder Head Temperature
(CHT) sensor jumper
harness
32 W701571 Heater outlet tube stud bolt
33 18663 Heater outlet tube
34 6051 Cylinder head gasket - RH
35 6049 Cylinder head - RH
36 9448 Exhaust manifold gasket (2 37 9430 Exhaust
required) manifold -
RH
38 W701706 Exhaust manifold nut (8
required)
39 W707747 Exhaust manifold stud (8
required)
assembly - RH
41 W701520 VCT oil control solenoid
42 6279 Camshaft phaser and
sprocket bolt
43 - Camshaft phaser and
sprocket (part of 6A257)
of 6049)

45 N807834 Camshaft bearing cap bolt

(10 required)
of 6049) (4 required)
47 6250 Camshaft - RH
48 HJFS-24FP- Spark plug (4 required)
49 12029 Ignition coil (4 required)
50 W711062 Ignition coil bolt (8
required)
51 6582 Valve cover - RH
52 6763 Oil fill adapter
53 6766 Oil fill adapter cap
55 W503282 Ecrossover manifold
56 W503279 Thermostat housing bolt (2
required)
57 8592 Thermostat housing
58 N806807 Thermostat O-ring seal
59 8255 Thermostat
60 8C368 Engine coolant crossover
manifold assembly
61 9A474 Intake manifold vacuum
harness and support bracket
assembly
62 W710758 Intake manifold bolt (10
required)
63 W505427 Air intake resonator
assembly bolt
64 9F763 Air intake resonator
assembly
65 9424 Intake manifold assembly
66 6A664 PCV tube
68 9F695 PCV fitting
Engine - Front End
Engine - Front End 1469


1 6306 Crankshaft sprocket
2 6K297 Timing chain guide - LH
3 N605892 Timing chain guide l bolt - LH
4 6268 Timing chain - LH
5 6K255 Tensioner arm - RH
6 12A227 Ignition pulse wheel
7 W706447 Power steering pump bolt (2 required)
8 W715069 Power steering pump stud bolt
9 3A696 Power steering pump assembly
10 N808529 Engine front cover stud bolt (2 required)
11 W706605 Engine front cover bolt
12 N806177 Engine front cover bolt (9 required)
13 6C315 Crankshaft Position (CKP) sensor
14 N806155 CKP sensor bolt
17 N806165 Crankshaft pulley washer
18 6A340 Crankshaft pulley bolt
19 8509 Coolant pump pulley
21 N808794 Coolant pump bolt (4 required)
22 8501 Coolant pump
24 8678 Accessory drive belt pulley
25 N806155 Camshaft Position (CMP) sensor bolt (2 required)
26 6B288 CMP sensor (2 required)
27 W709573 Engine front cover stud bolt (3 required)
28 W500110 Radio ignition interference capacitor bolt (2 required)
29 18801 Radio ignition interference capacitor (2 required)
30 6019 Engine front cover
31 N606543 Timing chain tensioner bolt - RH (2 required)
Engine - Front End 1470

32 6L266 Timing chain tensioner - RH

33 W503282 Timing chain guide bolt - RH (2 required)
34 6268 Timing chain - RH
35 6L266 Timing chain guide - RH
36 N606543 Timing chain tensioner bolt - LH (2 required)
37 6M269 Timing chain tensioner - LH
38 6M274 Tensioner arm - LH
39 N605892 Timing chain guide upper bolt - LH
Engine - Lower End
ellpadding="3" cellspacing="0" border="1">ItemPart NumberDescription1-Upper compression ring (part

of 6148) (8 required)2-Lower compression ring (part of 6148) (8 required)3-Outer oil control ring (part of
6148) (8 required)4-Inner oil control ring (part of 6148) (8 required)5-Outer oil control ring (part of 6148) (8
required)66140Piston pin retainer (16 required)76135Piston pin (8 required)86108Piston (8
required)96200Connecting rod assembly (8 required)106211Connecting rod bearing (8
required)116K301Crankshaft rear seal retainer plate12N806155Crankshaft rear seal retainer plate bolt (6
required)136701Crankshaft rear seal146310Crankshaft oil slinger156375Flexplate166379Flexplate bolt (8
required)176731Oil filter186890Oil filter threaded adapter19W714716Oil filter adapter stud
bolt20N806156Oil filter adapter bolt (3 re219278Engine Oil Pressure (EOP) switch226881Oil filter
adapter236840Oil filter adapter gasket24W701605Oil pan bolt (16 required)256675Oil pan266710Oil pan
gasket27N605904Oil pump screen and pickup tube bolt28N806155Oil pump screen and pickup tube bolt (2
required)296622Oil pump screen and pickup tube30N806180Oil pump screen and pickup tube
spacer316345Crankshaft main bearing cap stud326345Crankshaft main bearing cap bolt (9
required)336A346Crankshaft main bearing dowel (10 required)346345Crankshaft main bearing cap bolt (10
required)35-Crankshaft main bearing cap (part of 6010) (5 required)36-Crankshaft bearing - lower (part of
6D309) (5 required)37-Crankshaft thrust washer - lower (part of
6A355)386303Crankshaft39N806201Crankshaft key40-Crankshaft thrust washer - upper (part of 6A355) (2
required)41-Crankshaft bearing - upp (4 required)42-Crankshaft bearing - upper (part of
6D309)43-Connecting rod cap part of 6200 (8 required)446211Connecting rod bearing (8 required)456600Oil
pump46N806183Oil pump bolt (3 required)476010Cylinder block48W500225Knock Sensor (KS) bolt (2
Engine - Lower End 1471

required)4912A699KS (2 required)
NOTICE: Early build vehicle cooling systems are filled with Motorcraft Premium Gold Engine
Coolant. Late build vehicle cooling systems are filled with Motorcraft Specialty Orange Engine
Coolant. Do not mix coolant types. Mixing coolant types degrades the corrosion protection of the
coolant. Failure to follow these instructions may damage the engine or cooling system.
1. Record the main bearing code found on the front of the engine block.
2. Record the main bearing code found on the back of the crankshaft.
3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the
required bearing grade for each main bearing.
Read the first letter of the engine block main bearing code and the first letter of the crankshaft
main bearing code.
Read down the column below the engine block main bearing code letter, and across the row
next to the crankshaft main bearing code letter, until the 2 intersect. This is the required
bearing grade for the No. 1 crankshaft main bearing.
As an example, if the engine block code letter is F and the crankshaft code letter is D, the
correct bearing grade for this main bearing is a 2.
Repeat this process for the remaining 4 main bearings.
4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit
Chart, Oversize Bearings to determine the required bearing grade for each main bearing.

5. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint
and foreign material. Also, make sure the coolant and oil passages are clear.
Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean
engine oil.
6. NOTE: The upper thrust washers are shown for location purposes only. Do not install the upper
thrust washers until the crankshaft is installed. Refer to the following 2 steps.
Install the crankshaft onto the upper crankshaft main bearings.
7. NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the
crankshaft thrust surface).
Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No.
5 main boss.

8. NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the
crankshaft surface).
Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No.
5 main boss.
9. NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.
NOTE: The oil groove on the thrust washer must face toward the rear of the engine (crankshaft
surface).
Install the lower crankshaft thrust washer to the back side of the No. 5 main bearing cap, with oil
grooves facing the crankshaft surface.
10. Install the crankshaft lower main bearings into the main bearing caps and lubricate them with clean
engine oil. Locate the main bearing cap on the cylinder block and, keeping the cap as square as
possible, alternately draw the cap down evenly using the cap fasteners.
11. Install the 10 dowel pins so the flat sides face the crankshaft.
12. Install the 10 vertical main bearing cap fasteners and tighten in 2 stages, in the sequence shown.

13. Install the 10 side bolts and tighten them in 2 stages, in the sequence shown.
14. Assemble the 8 pistons. For additional information, refer to Piston in this section.
15. Make sure the ring gaps (oil spacer - A, oil ring - B, compression ring - C) are correctly spaced
around the circumference of the piston.
16. Make sure the dimple in the piston faces the front of the engine.

17. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or
engine damage may occur.
NOTE: The following piston installation steps are for all 8 connecting rods, connecting rod bearings
and pistons. Only one connecting rod, connecting rod bearing and piston is shown.
Using the Piston Ring Compressor and the Connecting Rod Installer, install the connecting rod with
the upper connecting rod bearing in place.
Lubricate the piston and ring with clean engine oil.

Lubricate the rod bearings with clean engine oil.
18. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or
engine damage may occur.
Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Installer.
19. NOTICE: The rod cap installation must keep the same orientation as marked during
disassembly or engine damage may occur.
NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod
ends. Excessive bearing clearance will result if not mated correctly.
Position the lower bearing and connecting rod, and install the 16 new bolts loosely.
20. Check the piston-to-cylinder block and piston ring clearances. For additional information, refer to
Section 303-00 .
21. NOTE: Main bearing caps are removed for clarity.
Tighten the 16 bolts in 2 stages, in the sequence shown.

22. Position the oil pump and install the 3 bolts.

23. Install the oil pump screen and pickup tube spacer.

26. NOTICE: Make sure all coolant residue and foreign material are cleaned from the block surface
and cylinder bore.
NOTICE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The
gasket must be installed dry or engine damage may occur.
NOTICE: The cylinder head bolts must be discarded and new bolts installed. They are a
tighten-to-yield design and cannot be reused.
NOTE: Do not turn the crankshaft until instructed to do so.
Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over
the dowels and install the 20 cylinder head bolts loosely.
Tighten the 20 bolts in 3 stages, in the sequence shown.


28. Remove the Cylinder Head Remover/Installer from the LH cylinder head.
29. Remove the Cylinder Head Remover/Installer from the RH cylinder head.
30. Install the 24 hydraulic lash adjusters into the RH and LH cylinder heads.
Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.

Install the 5 LH and 5 RH camshaft bearing caps in their original locations.



Install the camshaft phaser and sprockets and new camshaft phaser and sprocket bolts finger-tight.
Using the Cam Phaser Locking Tool, tighten the LH and RH camshaft phaser and sprocket bolts in 2
stages.


may result.
NOTICE: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks,
tears, separation from the tensioner body or permanent compression of the seal bead is
observed, install a new tensioner or engine damage may occur.
36. Install the Hydraulic Chain Tensioner Retaining Clip on the tensioner to hold the plunger in during
installation.
timing marks.
40. Position the LH and RH timing chain guides and install the 4 bolts.

Position the timing chain on the camshaft phaser and sprocket with the timing mark positioned
between the 2 copper (marked) chain links.
and 2 bolts.
44. Remove the Hydraulic Chain Tensioner Retaining Clip from the LH timing chain tensioner.

Position the RH timing chain on the camshaft phaser and sprocket. Make sure the timing mark is
positioned between the 2 copper (marked) chain links.
48. Remove the Hydraulic Chain Tensioner Retaining Clip from the RH timing chain tensioner.

49. As a post-check, verify correct alignment of all timing marks.
Lubricate the camshaft roller followers with clean engine oil prior to installation.

NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the
sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep.
Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes,
whichever is longer. Failure to follow this procedure may cause future oil leakage.
NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before
installation.
Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the
locations shown.
53. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto
the dowels. Install the fasteners finger-tight.


55. NOTICE: Do not rotate the coolant pump housing once the coolant pump has been positioned in
the cylinder block. Damage to the O-ring seal will occur.
Using a new O-ring seal, position the coolant pump and install the bolts loosely.
Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal onto the
coolant pump. Use the same type of coolant that was drained from the system.

56. Tighten the 4 coolant pump bolts.

57. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.
58. Using the Crankshaft Vibration Damper Installer, Front Cover Oil Seal Installer and Crankshaft Front
Oil Seal Installer, install a new crankshaft front seal.

61. Tighten the new crankshaft pulley bolt in 4 stages.

62. Position the accessory drive belt tensioner and install the 3 bolts.
63. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the 7 bolts.
NOTE: Clean and inspect the mating surfaces, and install a new gasket.
Position the oil filter adapter and install the 3 bolts and the studbolt.

65. NOTE: Lubricate the oil filter gasket with clean engine oil.
Install a new oil filter.
Tighten the oil filter until the gasket makes contact, then use an oil filter strap wrench to
tighten the filter an additional 270 degrees.
Install 16 new exhaust manifold studs.
67. Position a new gasket, the LH exhaust manifold and tighten the 8 nuts in the sequence shown.
68. Position a new gasket, the RH exhaust manifold and tighten the 8 nuts in the sequence shown.

69. Position the RH engine support insulator-to-cylinder block bracket and install the 3 bolts.
means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
Use a plastic scraping tool to remove all traces of old sealant.
Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the
Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
Position the RH valve cover and gasket on the cylinder head and tighten the 8 bolts in the sequence
shown.

Position the LH valve cover and gasket on the cylinder head and tighten the 9 bolts in the sequence
shown.

76. Install the oil level indicator tube and the bolt.
Install a new O-ring seal and lubricate the O-ring seal with clean engine oil prior to
installation.
77. Position the LH engine support insulator-to-cylinder block bracket and install the 3 bolts.
78. NOTE: Do not reuse the O-ring seals.
NOTE: Lubricate the O-ring seals with clean engine coolant prior to installation. Use the same type
of coolant that was drained from the system.
Slide the coolant tube forward with the new O-ring seals into the cylinder block.
79. Install the coolant tube stud bolt.


80. Install the 2 Knock Sensor (KS) and the 2 bolts.

Install the 8 ignition coils and the 8 bolts.
Verify that the ignition coil spring is correctly located inside the ignition coil boot and that
there is no damage to the tip of the boot.
Apply a light coat of dielectric compound to the inside of the ignition coil boots prior to
installation.
82. Position the intake manifold vacuum tube support bracket and install the bolt.

86. Using a floor crane, remove the engine from the engine stand.
means to clean the aluminum retainer plate. These tools cause scratches and gouges, which
make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Failure to follow
this procedure can cause future oil leakage.
Inspect the crankshaft rear seal retainer plate. Clean the mating surface for the rear seal retainer plate
with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
88. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To
clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on
the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer.
Failure to follow this procedure may cause future oil leakage.
Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the crankshaft rear seal retainer
sealing surface.
89. Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.

90. Tighten the bolts in the sequence shown.

Inspect the oil pan. Clean the mating surface for the oil pan with silicone gasket remover and metal
surface prep. Follow the directions on the packaging.
Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing
surface.
Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.

94. Install the oil pan gasket and the oil pan and loosely install the 16 bolts.
95. Tighten the 16 bolts in 3 stages, in the sequence shown.

96. NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.
Using the 2 Crankshaft Rear Oil Seal Installers, install a new crankshaft rear seal.

97. Using the 2 Crankshaft Rear Oil Seal Installers and the Crankshaft Rear Oil Slinger Installer, install
the crankshaft rear oil slinger.
98. Install the spacer plate.
99. Install the flexplate and the 8 bolts in the sequence shown.


INSTALLATION Procedure revision date: 08/12/2010
Engine
Special Tool(s)
Installer, Power Steering Pump Pulley

211-185 (T91P-3A733-A)

303-F047 (014-00073) or equivalent

Material
Item Specification
(Canada)
XO-5W20-QSP (US);
TA-26
1. Using a suitable floor crane, position the engine assembly into the vehicle.
2. NOTICE: Only use hand tools when tightening the engine support insulator through bolt or the
engine support insulator may be damaged.
Apply threadlock to the bolt threads and install the LH engine support insulator bolt.
3. NOTICE: Only use hand tools when tightening the engine support insulator nuts or the engine
support insulator may be damaged.
Engine 1499
NOTE: Make sure the RH engine support insulator mating surfaces and the washer mating surface
are free of foreign material and corrosion before installation. Install a new washer.
Apply threadlock to the stud threads and install the RH engine support insulator washer and nuts.
l>
5. NOTE: The upper 2 transmission-to-engine bolts will be installed later.
Install the lower 5 transmission-to-engine bolts.
6. Tighten the 2 transmission mount nuts.

7. Install 4 new torque converter-to-flexplate nuts.

Engine 1500
8. Install the cylinder block opening cover.
9. Install the flexplate inspection cover and the 2 bolts.

10. Position the A/C compressor and install the 3 bolts.

11. Position the transmission cooler tube support bracket, the starter wiring harness support bracket and
install the nut.
12. Position the starter wiring harness and rear support bracket and install the bolt.
Engine 1501
13. Install the starter. For additional information, refer to Section 303-06 .
14. If equipped, connect the block heater electrical connector.
15. Install the 4 exhaust Y-pipe flange nuts (2 RH and 2 LH).

16. NOTE: On Four-Wheel Drive (4WD) vehicles, reposition the transfer case vent hose.
Position the fuel and Evaporative Emission (EVAP) tube support bracket and install the upper 2
transmission-to-engine bolts.
17. Position the engine wiring harness onto the engine.
18. Connect the transmission wiring harness retainer to the intake manifold vacuum tube support bracket.
Engine 1502
19. Connect the LH Camshaft Position (CMP) sensor, radio interference capacitor and Variable Camshaft
Timing (VCT) solenoid electrical connectors, the radio interference capacitor electrical connector
retainer and the 2 wiring harness retainers.
20. Connect the Cylinder Head Temperature (CHT) electrical connector.
21. Connect the LH Knock Sensor (KS) electrical connector.
22. Connect the RH KS electrical connector and the heater coolant hose.
23. Connect the 4 RH ignition coil electrical connectors and the 2 engine wiring harness retainers to the
RH valve cover studs.
24. Connect the RH VCT solenoid and the RH radio ignition interference capacitor electrical connectors.
Engine 1503
25. Connect the RH CMP sensor electrical connector and the 2 wiring harness retainers.
26. Position the ground strap and install the bolt.

27. Connect the PCM electrical connector and the engine wiring harness retainer.
28. Connect the engine harness electrical connector and wiring harness retainer.
29. Position the power steering pump and reservoir assembly and install the 2 bolts and the stud bolt.
Engine 1504
30. Using the Power Steering Pump Pulley Installer, install the power steering pump pulley.
31. Position the Power Steering Pressure (PSP) hose support bracket and install the nut.
32. NOTICE: While servicing the power steering system, care should be taken to prevent the entry
of foreign material or failure of the power steering components may result.
Position the power steering fluid tubes and install the bolt.
33. Connect the A/C compressor electrical connector and the wiring harness retainer.
34. Connect the Engine Oil Pressure (EOP) switch electrical connector and the wiring harness retainers to
the oil pan bolt, the power steering pump stud bolt and the engine block.
Engine 1505
35. Connect the Crankshaft Position (CKP) sensor electrical connector.
36. Position the accessory drive belt onto the accessory drive pulleys.
37. Position the Power Distribution Box (PDB) and wiring harness onto the engine.
38. Install the cooling module. For additional information, refer to Section 303-03 .
damage.
Install the intake manifold. For additional information, refer to Intake Manifold in this section.
40. NOTE: Align the index marks made during hood removal.
Position the hood and install the 4 bolts.
41. Fill the crankcase with clean engine oil.
42. Evacuate and charge the A/C system. For additional information, refer to Section 412-00 .
43. Fill and bleed the power steering system. For additional information, refer to Section 211-00 .
44. If the engine was disassembled, use the scan tool to perform the Misfire Monitor Neutral Profile
Correction procedure following the on-screen instructions.
Engine 1506
Engine 1507
Cylinder Head
Special Tool(s)
Alignment Pins, Cylinder Head

303-1040 (SR-015486)

303-1039

303-448 (T93P-6303-A)

303-635

303-102 (T74P-6316-B)

303-335 (T88T-6701-A)

303-F047 (014-00073) or equivalent
Locking Tool, Cam Phaser Sprocket

303-1046

303-572 (T97T-6000-A)
General Equipment
Hydraulic Chain Tensioner Retaining Clip -

1L3Z-6P250-AA
Material
Item Specification
ZC-31-A
Motorcraft Premium Gold WSS-M97B51-A1
Engine Coolant
Cylinder Head 1508


(Canada)
XO-5W20-QSP (US);
Engine Coolant
Dielectric Compound
XG-3-A
TA-30
Remover
ZC-30
Threadlock 262 WSK-M2G351-r>
TA-26
All cylinder heads
1. NOTICE: Make sure all coolant residue and foreign material are cleaned from the block surface
and cylinder bore. Failure to follow this instruction may result in engine damage.
NOTE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket
must be installed dry.
NOTE: The cylinder head bolts must be discarded and new bolts installed. They are a tighten-to-yield
design and cannot be reused.
NOTE: Do not turn the crankshaft until instructed to do so.
Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over
the dowels and install the 20 cylinder head bolts loosely.
2. Tighten the 20 bolts in 3 stages, in the sequence shown.

RH shown, LH similar.
Cylinder Head 1509

LH cylinder head
3. Remove the Cylinder Head Remover/Installer from the LH cylinder head.
4. NOTE: The hydraulic lash adjusters must be installed in their original locations.
Install the hydraulic lash adjusters into the LH cylinder head.
5. Install 8 new LH exhaust manifold-to-cylinder head studs.

6. Position new gaskets, the LH exhaust manifold and tighten 8 new nuts in the sequence shown.
Cylinder Head 1510

RH cylinder head
7. Remove the Cylinder Head Remover/Installer from the RH cylinder head.
8. NOTE: The hydraulic lash adjusters must be installed in their original locations.
Install the hydraulic lash adjusters into the RH cylinder head.
9. Install 8 new RH exhaust manifold-to-cylinder head studs.

10. Position 2 new gaskets, the RH exhaust manifold and tighten the 8 new nuts in the sequence shown.
Cylinder Head 1511

11. NOTICE: Early build vehicle cooling systems are filled with Motorcraft Premium Gold
Engine Coolant. Late build vehicle cooling systems are filled with Motorcraft Specialty
Orange Engine Coolant. Do not mix coolant types. Mixing coolant types degrades the corrosion
protection of the coolant. Failure to follow these instructions may damage the engine or cooling
system.
NOTE: Install 2 new O-ring seals and lubricate the O-ring seals with clean engine coolant. Use the
same type of coolant that was drained from the system.
Install the coolant tube and the stud bolt.
12. Position the ground strap and install the nut.

All cylinder heads

Install the LH and RH camshaft bearing caps in their original locations. ul type="disc">
15. Lubricate the camshaft bearing caps with clean engine oil.
Position the 2 front camshaft bearing caps.
Position the remaining 8 camshaft bearing caps.
Cylinder Head 1512

NOTE: The RH and LH camshaft phaser and sprockets are similar. Refer to the single timing mark to
identify the RH camshaft phaser and sprocket and the L timing mark to identify the LH camshaft
phaser and sprocket.
Install the camshaft phaser and sprockets and new camshaft phaser and sprocket bolts finger-tight.
Using the Cam Phaser Sprocket Locking Tool, tighten the LH and RH camshaft phaser and sprocket
bolts in 2 stages.

Cylinder Head 1513

tensioner-sealing bead must be inspected for seal integrity. Any cracks, tears, cuts or separation
from the tensioner body, or permanent compression of the seal bead, will require replacement
of the tensioner or engine damage may occur.
Inspect the RH and LH timing chain tensioners.
Install new tensioners, as necessary.
will result.
19. Install a Hydraulic Chain Tensioner Retaining Clip on the tensioner to hold the plunger in during
installation.
timing marks.
Cylinder Head 1514

24. Position the LH and RH timing chain guides and install the 4 bolts.
Position the timing chain on the camshaft phaser and sprocket with the camshaft phaser and sprocket
timing mark positioned between the 2 copper (marked) chain links.
and the 2 bolts.
Cylinder Head 1515

28. Remove the Hydraulic Chain Tensioner Retaining Clip from the LH timing chain tensioner.
Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark
is positioned between the 2 copper (marked) chain links.
Cylinder Head 1516

32. Remove the Hydraulic Chain Tensioner Retaining Clip from the RH timing chain tensioner.
33. NOTE: The RH and LH camshaft phaser sprockets are similar. Refer to the single timing mark to
identify the RH camshaft phaser sprocket and the L timing mark to identify the LH camshaft phaser
sprocket.
As a post-check, verify correct alignment of all timing marks.
NOTE: Lubricate the roller followers with clean engine oil prior to installation.
Cylinder Head 1517

NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the
sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep.
Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before
installation.
Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the
locations shown.
37. Install 3 new engine front cover gaskets on the engine front cover. Position the engine front cover
onto the dowels. Install the 15 fasteners finger-tight.
Cylinder Head 1518


39. Loosely install the 4 bolts, then tighten the bolts in 2 stages, in the sequence shown.
Cylinder Head 1519

the packaging. Failure to follow this procedure can cause future oil leakage.
42. NOTICE: Install the valve cover carefully, or the Variable Camshaft Timing (VCT) solenoid
may be damaged.
Position the RH valve cover and new gasket on the cylinder head and tighten the 8 fasteners in the
sequence shown.
the packaging. Failure to follow this procedure can cause future oil leakage.
Cylinder Head 1520

45. NOTICE: Install the valve cover carefully, or the Variable Camshaft Timing (VCT) solenoid
may be damaged.
Position the LH valve cover and new gasket on the cylinder head and tighten the 9 fasteners in the
sequence shown.
46. Position the oil level indicator tube and install the bolt.
Install a new O-ring seal and lubricate the O-ring seal with clean engine oil prior to
installation.
47. NOTE: Clean the engine support insulator-to-cylinder block mating surfaces of any dirt or foreign
material prior to installation.
If equipped with cylinder block drain plugs, position the RH engine support insulator and install the 3
bolts.
Apply threadlock 262 to the bolt threads prior to installation.

Cylinder Head 1521

48. Lubricate the engine front cover and the new crankshaft seal inner lip with clean engine oil.
49. Using the Crankshaft Front Oil Seal Installer, the Crankshaft Vibration Damper Installer and the Front
Cover Oil Seal Installer, install the new crankshaft front seal into the engine front cover.
Cylinder Head 1522

53. Position the accessory drive belt tensioner and install the 3 bolts.
54. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the 7 bolts.
Install the 8 ignition coils and the 8 bolts.
Verify that the ignition coil spring is correctly located inside the ignition coil boot and that
there is no damage to the tip of the boot.
Apply a light coat of dielectric compound to the inside of the ignition coil boots prior to
installation.
56. Position the intake manifold vacuum tube support bracket and install the bolt.
Cylinder Head 1523

59. Using a floor crane, remove the engine from the engine stand.
60. NOTICE: Do not use the oil pan to support the engine or oil pan and oil pan gasket damage may
occur.
Lower and support the engine assembly on wood blocks.
62. Install the engine. For additional information, refer to Engine in this section.
Cylinder Head 1524

Cylinder Head 1525

SECTION 303-03: Engine Cooling 2011 Expedition, Navigator Workshop Manual

Material

Motorcraft Metal - -
Surface Prep
ZC-31-A
Motorcraft ESR-M14P7-A -
Premium Cooling
System Flush
VC-1
Motorcraft - -
Silicone Gasket
Remover
ZC-30
Motorcraft WSS-M97B44-D Base radiator without
Specialty Orange aux. rear heat - 15.5L
Engine Coolant (16.4 qt) a
VC-3-B (US); Base radiator with aux.
CVC-3-B (Canada) rear heat - 18L (19 qt) a
Heavy duty trailer tow
radiator without aux. rear
heat - 16L (16.9 qt) a
Heavy duty trailer tow
radiator with aux. rear
heat - 18.5L (19.5 qt) a
a Includes coolant expansion tank fluid level between the COLD AND HOT FILL LEVEL lines.
Item Specification
Pressure Tests
Complete cooling system maximum pressure 110 kPa (16 psi)
Pressure relief cap 110 kPa (16 psi)
Radiator (out of vehicle) 138 kPa (20 psi)
Thermostat Opening Temperatures
Starts to open 86.7-90.6C (188-195F)
Fully open 100C (212F)
DescriptionNmlb-ftlb-inA/C condenser fitting nut and bolt15-133Battery Junction Box (BJB)

bolts10-89Battery power cable nut10-89Block heater retaining screw2-18Coolant expansion tank
Cylinder Head 1526

bolts15-133Coolant pump bolts2518-Coolant pump pulley bolts2518-Cooling fan motor and shroud
bolts7-62Cooling module bolts2518-Hood latch assemblvalign="top" align="center">2518-Horn assembly
bolt10-89Power Distribution Box (PDB) support bracket bolts10-89Power steering fluid reservoir stud
bolt11-97Radiator assembly-to-radiator support bolts15-133Thermostat housing bolts10-89
Cylinder Head 1527


Engine Cooling
NOTICE: Vehicle cooling systems are filled with Motorcraft Specialty Orange Engine Coolant.
Always fill the cooling system with the manufacturer's specified coolant. If a non-specified coolant has
been used the cooling system must be chemically flushed. Refer to Cooling System Flushing in this
section. Failure to follow these instructions may damage the engine or cooling system.
NOTICE: During normal vehicle operation, Motorcraft Specialty Orange Engine Coolant may change
color from orange to pink or light red. As long as the engine coolant is clear and uncontaminated, this
color change does not indicate the engine coolant has degraded nor does it require the engine coolant to
be drained, the system to be flushed, or the engine coolant to be replaced.
The cooling system consists of the following components:
Block heater (located in the lower left hand corner of the engine block)
Coolant crossover manifold assembly (located in front of the intake manifold)
Coolant expansion tank
Cooling fan motor and shroud
Radiator
Radiator draincock (located in the lower right hand corner)
Upper and lower radiator hoses
Bypass coolant hose
Coolant pump
Coolant thermostat
The coolant pump:
circulates the coolant.
The coolant thermostat:
controls coolant temperature.

allows quicker engine warm-up.
The coolant expansion tank:
holds surplus coolant when hot.

allows coolant expansion.
replenishes coolant to the system.
The fan motor:
operates only when the ignition switch is in the RUN position.

will not operate with the ignition switch in the OFF position.
The radiator:
cannot be serviced. Install a new radiator.

allows excess heat to be transferred to the air.
The optional block heater:
Engine Cooling 1528

electrical heating element is installed in the core plug opening.
uses a standard 110V electrical supply
keeps the engine coolant warm during cold weather.
NOTICE: Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion
protection to the engine and cooling components. In order to obtain these protections, the engine
coolant must be maintained at the correct concentration and fluid level in the degas bottle. Failure to
follow these instructions may damage the engine or cooling system.
When adding engine coolant, use a 50/50 mixture of engine coolant and distilled water. A coolant
concentration of 50% provides freeze point protection down to -37C (-34F).
To maintain the integrity of the coolant and the cooling system:
add Motorcraft Specialty Orange Engine Coolant. Do not mix coolant types.
do not add alcohol, methanol or brine or any engine coolants mixed with alcohol or methanol
antifreeze. These can cause engine damage from overheating or freezing.
do not mix with recycled coolant. Use of such a coolant may harm the engine and cooling system
components.
Coolant Flow Diagram, Expedition and Navigator without Auxiliary Heater
NOTE: Black arrows indicate hot, white arrows indicate cold.

2 18K580 Heater outlet hose
3 18K579 Heater inlet hose
5 18476 Heater core
7 8575 Thermostat
9 18663 Heater coolant outlet tube
10 6050 LH cylinder head
11 6083 LH cylinder head gasket
12 8A080 Coolant expansion tank
13 8N029 Coolant overflow hose
Coolant Flow Diagram, Expedition and Navigator without Auxiliary Heater 1529

15 6010 Cylinder block
17 6049 RH cylinder head
18 8B273 Lower radiator hose
19 8B274 Upper radiator hose
20 8005 Radiator
Coolant Flow Diagram, Expedition and Navigator with Auxiliary Heater

5 18476 Heater core
7 8575 Thermostat
10 18476 Auxiliary heater core
11 18K470 Auxiliary heater tubes
Coolant Flow Diagram, Expedition and Navigator with Auxiliary Heater 1530

23 8005 Radiator
Coolant Flow Diagram, Expedition EL and Navigator L with Auxiliary Heater

5 18476 Heater core
7 8575 Thermostat
10 18476 Auxiliary heater core
Coolant Flow Diagram, Expedition EL and Navigator L with Auxiliary Heater 1531
23 8005 Radiator
Coolant Flow Diagram, Expedition EL and Navigator L with Auxiliary Heater 1532

Engine Cooling
Special Tool(s)
3-Way HD Antifreeze Coolant Test Kit

Coolant/Battery Refractometer
ROB75240 or equivalent
Radiator Tester
STN12270 or equivalent
UView Combustion Leak Tester

UVU560000-R or equivalent

software with appropriate hardware or
Material
Item Specification
Engine Coolant
Engine coolant flows primarily from the engine to the radiator circuit and back to the coolant pump. Coolant
is sent from the coolant pump through the engine block and cylinder heads. A separate circuit from the engine
also feeds the heater core with coolant. The coolant pump is operated by engine rotation through a pulley
which is driven by the accessory drive belt to circulate the coolant. The coolant thermostat is a control valve
actuated by coolant temperature. When the thermostat is closed, coolant flow bypasses the radiator circuit and
returns to the coolant pump. When the thermostat is opened, coolant flows through the radiator circuit in order
to transfer engine-generated heat to the outside air.
The coolant expansion tank holds surplus coolant, allows for coolant expansion and replenishes coolant to the
cooling system. It is equipped with a non-pressurized cap which allows coolant to be added to the tank to keep
it filled to prescribed levels.
The cooling fan draws air through the radiator to help cool the engine coolant as it passes through the radiator.
The thermostat monitor is a function of the PCM and is designed to verify correct thermostat operation. The
monitor is executed once per drive cycle and has a monitor run duration of 300-800 seconds. If a malfunction
occurs, DTC P0125 or P0128 is set, and the malfunction indicator lamp is illuminated.
Engine Cooling 1533

NOTICE: The engine cooling system is filled with Motorcraft Specialty Orange Engine Coolant.
Always fill the cooling system with the manufacturer's specified coolant. Chemically flush the cooling
system if a non-specified coolant has been used. Refer to Cooling System Flushing in this section.
Failure to follow these instructions may damage the engine or cooling system.
NOTICE: The engine cooling system is filled with Motorcraft Specialty Orange Engine Coolant. Do
not mix coolant types. Mixing coolant types degrades the corrosion protection of Motorcraft
Specialty Orange Engine Coolant.
NOTE: During normal vehicle operation, Motorcraft Specialty Orange Engine Coolant may change color
from orange to pink or light red. As long as the engine coolant is clear and uncontaminated, this color change
does not indicate the engine coolant has degraded nor does it require the engine coolant to be drained, the
system to be flushed, or the engine coolant to be replaced.
2. Visually check the engine coolant level at the coolant expansion tank when the system is cold.
3. Make sure the pressure relief cap is installed correctly.
4. Record any cooling system DTCs retrieved. Refer to the DTC Chart in this section for DTC
descriptions.
5. NOTE: Take note of any coolant odor or steam coming from cooling system components.
If the system coolant is filled correctly and no DTCs associated with fail-safe cooling are retrieved,
verify the customer's concern by operating the engine to duplicate the condition.
6. NOTE: Refer to the coolant flow diagram in the Description and Operation, Engine Cooling portion
of this section.
Visually inspect for obvious signs of mechanical or electrical damage.
Leaks or weeps at: Inoperative or damaged:

Hoses Wiring, connectors or
Tubes PCM
Clamp joints Electric cooling fan
Gaskets Cylinder Head
O-rings Temperature (CHT)
Engine Cooling 1534

Thermostat housing sensor

Radiator Vehicle Speed Sensor
Pressure relief cap (VSS)
Coolant pump
Heater core (wet floor or coolant odor in vehicle)
Coolant crossover manifold assembly
Oil filter adapter
Cylinder block core plugs
Cylinder head core plugs
Block heater (if equipped)

Cracked or damaged:
Hoses
Tubes
Hose clamps
Thermostat housing
Radiator
Pressure relief cap
Cooling fan
Coolant pump
Oil filter adapter
Block heater (if equipped)
Restricted airflow through the A/C condenser/radiator
Drive belt loose, worn or installed incorrectly
Broken or weak drive belt tensioner
Excessive white or light gray exhaust smoke (may have burnt
coolant odor)
Coolant in engine oil
Engine oil in coolant
Coolant in automatic transmission fluid
Automatic transmission fluid in coolant
7. If the inspection reveals an obvious concern that can be readily identified, repair it as necessary. Test
8. NOTE: During normal vehicle operation, Motorcraft Specialty Orange Engine Coolant may change
color from orange to pink or light red. As long as the engine coolant is clear and uncontaminated, this
color change does not indicate the engine coolant has degraded nor does it require the engine coolant
to be drained, the system to be flushed, or the engine coolant to be replaced.
Inspect the coolant condition.
1. Inspect the coolant color.

Discoloration may indicate that incorrect coolant may have been added to the system.
Use of incorrect (green or yellow in color) coolant degrades the corrosion protection
of Motorcraft Specialty Orange Engine Coolant. Addition of Motorcraft
Specialty Green Engine Coolant may cause the color to appear to be a murky
green-brown color. The addition of Motorcraft Premium Gold Coolant, however,
Engine Cooling 1535

may not change the color or appearance of the orange colored coolant. Detection of
contamination with Premium Gold Engine Coolant is determined by the presence of
nitrite. If contamination with Motorcraft Premium Gold Engine Coolant is
suspected, test the coolant with the 3-Way HD Antifreeze Coolant Test Kit. Follow
the directions in/on the packaging with regard to nitrite testing. If the incorrect
coolant has been added to the cooling system (nitrite is present), flush the system and
refill with the correct mixture of distilled water and Motorcraft Specialty Orange
Engine Coolant. Refer to Cooling System Flushing in this section.
A darker orange with the presence of debris could indicate a commercially available
stop leak may have been used and could result in loss of coolant flow to critical parts
of the engine. If sediment is present in the coolant sample, flush the system and refill
with the correct mixture of distilled water and Motorcraft Specialty Orange
A light or reddish brown color indicates that rust may be present in the cooling
system. Flush the system and refill with the correct mixture of distilled water and
Motorcraft Specialty Orange Engine Coolant. Refer to Cooling System Flushing
in this section.
An iridescent sheen on top of the coolant could indicate a trace of oil is entering the
system. For engine diagnosis, refer to Section 303-00 . Flush the cooling system and
refill with the correct mixture of distilled water and Motorcraft Specialty Orange
A milky brown color may indicate that engine oil is entering the cooling system.
Pressure test the cooling system. Refer to the Component Tests in this section. If
engine oil is suspected, the cause of the leak may be internal to the engine. For engine
diagnosis, refer to Section 303-00 . Flush the cooling system and refill with the
correct mixture of distilled water and Motorcraft Specialty Orange Engine
Coolant. Refer to Cooling System Flushing in this section.
2. If the engine coolant appearance is acceptable, test the engine coolant freezing point range
with the Coolant/Battery Refractometer. The freezing point should be in the range -50C to
-26C (-58F to -15F). If the vehicle is driven in cold climates less than -37C
(-34F), it may be necessary to increase the coolant concentration to get adequate freeze
protection. Recommended coolant concentration is 50/50 engine coolant to distilled water.
Maximum coolant concentration is 60/40 for cold weather areas.
Minimum coolant concentration is 40/60 for warm weather areas.
3. Adjust coolant range and level if necessary:
If coolant is low, add specified coolant mixture only.
If the engine coolant tests too weak, remove some of the engine coolant and add
undiluted engine coolant until the readings are within acceptable levels.
If the engine coolant tests strong, remove some of the engine coolant and add distilled
water until the readings are within acceptable levels.
9. If an obvious cause for an observed or reported concern is found, correct the cause and test the system
for normal operation before proceeding to the next step.
Engine Cooling 1536


418-00 .
(CMDTCs).
14. Clear the CMDTCs and carry out the self-test diagnostics for the PCM.
15. If the DTCs recovered are related to the concern, go to the PCM DTC Chart. For all other PCM
DTCs, refer to Section 303-14 .
DTC Chart
PCM DTC Chart

P0217 Engine Coolant Over Temperature Condition GO to Pinpoint Test B .
P1285 Cylinder Head Over Temperature Condition GO to Pinpoint Test B .
P1299 Cylinder Head Over Temperature Protection GO to Pinpoint Test B .
Active
P0125 Insufficient Coolant Temperature For Closed GO to Pinpoint Test C .
Loop Fuel Control
P0128 Coolant Thermostat (Coolant Temperature GO to Pinpoint Test C .
Below Thermostat Regulating Temperature)
P0480 Fan 1, 2 or 3 Control Circuit, Respectively REFER to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual.
P0481
P0482
All Other REFER to Section 303-14 .
PCM DTCs
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test A: Loss of Coolant
Engine Cooling 1537

Normal Operation
The engine cooling system is a closed system that provides for coolant expansion and contraction and also
changes in pressure as coolant warms and cools with engine operation. Various gaskets, seals, hoses and
clamps contain coolant within the cooling system and keep other fluids and contaminants from entering the
cooling system.
Coolant loss can be attributed to either external or internal leaks anywhere within the cooling system.
For engine specific information, refer to Engine Cooling in the Description and Operation portion of this
section.

Coolant hoses or tubes
Hose clamps
Thermostat O-ring seal
Coolant pump O-ring seal
Thermostat housing
Radiator
Transmission fluid cooler (in radiator)
Pressure relief cap
Coolant pump leaking from weep hole
Heater core
Engine gaskets
Oil filter adapter
Block heater
PINPOINT TEST A: LOSS OF COOLANT

A1 CARRY OUT INSPECTION AND
VERIFICATION
Yes
Carry out the inspection and REPAIR as needed. TEST the system for normal operation.
verification procedure in this
section. No
Were any concerns found? GO to A2 .
A2 CHECK THE ENGINE
COOLANT LEVEL
Yes
NOTE: Allow the engine to cool GO to A3 .
before checking the engine
coolant level. No

Ignition OFF. ADJUST the engine coolant level as necessary. GO to A3 .

Visually inspect the engine
coolant level at the coolant
expansion tank.
Is the engine coolant level within
specifications?
A3 PRESSURE TEST THE ENGINE
COOLING SYSTEM
Yes
Pressure test the engine cooling REPAIR or INSTALL new components. TEST the system
system. Refer to Component for normal operation.
Tests, Cooling System Pressure
Test in this section. No
Does the engine cooling system GO to A4 .
leak externally?
A4 CHECK THE ENGINE
COOLANT FOR AN INTERNAL
LEAK
Yes
Inspect the engine coolant in the If engine oil is evident, GO to Section 303-00 for engine
coolant expansion tank and the diagnosis. If transmission fluid is evident, INSTALL a new
radiator for signs of engine oil or radiator. REPAIR the transmission as necessary. Refer to the
transmission fluid. appropriate section in Group 307 for the procedure. TEST
Is engine oil or transmission the system for normal operation.
fluid evident in the coolant?
No
GO to A5 .
A5 CHECK THE ENGINE OIL AND
TRANSMISSION FLUID FOR
COOLANT
Yes
Remove the oil level indicators If coolant is in the engine oil, GO to Section 303-00 . If
from the engine and the coolant is in the transmission fluid, INSTALL a new
transmission. radiator. REPAIR the transmission as necessary. Refer to the
Is coolant evident in the oil or appropriate section in Group 307 for the procedure.
transmission fluid?
No
GO to A6 .
A6 CHECK THE COOLING
SYSTEM FOR COMBUSTION GASES
Yes
NOTE: Use UView GO to Section 303-00 for engine diagnosis.
Combustion Leak Tester part
number UVU560000-R or No
equivalent. The cooling system is operational.
Using a cooling system
combustion gas leak tester,
following the instructions supplied
with the tester, check the coolant
for combustion gases.
Are combustion gases present?
Pinpoint Test B: The Engine Overheats
PINPOINT TEST A: LOSS OF COOLANT 1539

Normal Operation
The engine cooling system maintains engine temperatures during operation. Correct coolant flow through the
engine, radiator and remainder of cooling system passages and components is essential to maintaining a
correct engine temperature.
Engine overheating generally occurs when there is a disruption in the ability to control either coolant flow at
the proper rate, the inability to transfer heat from the engine through the coolant (including low coolant), or an
inability to transfer engine generated heat to the outside air through the radiator.
DTC P0217 (Engine Coolant Over Temperature Condition) Indicates an engine overheat
condition was detected by the Cylinder Head Temperature (CHT) sensor.
DTC P1285 (Cylinder Head Over Temperature Condition) Indicates an engine overheat
condition was sensed by the CHT sensor.
DTC P1299 (Cylinder Head Over Temperature Protection Active) Indicates an engine overheat
condition was detected by the CHT sensor. A failure mode effects management strategy called
fail-safe cooling was activated to cool the engine.

Low coolant level
External engine coolant leak
Airlock in system
Pressure relief cap installation
Restricted airflow through the A/C condenser/radiator
Internal engine coolant leak
Coolant condition/concentration
Accessory drive components
Non-OEM engine enhancement components
Electric cooling fan
Engine Coolant Temperature (ECT) gauge
Cylinder Head Temperature (CHT) sensor
Coolant pump
Coolant flow restriction
PINPOINT TEST B: THE ENGINE OVERHEATS

B1 CARRY OUT INSPECTION AND
VERIFICATION

Carry out the inspection and verification Yes

procedure in this section. REPAIR as needed. TEST the system for normal
Were any concerns found? operation.
No
GO to B2 .
B2 CHECK FOR DTCs
Yes
Check for DTC P0217, P1285 or P1299. GO to B3 .
Is DTC P0217, P1285 or P1299 present?
No
Actual engine overheating has not been verified.
CHECK the ECT gauge operation. REFER to
Section 413-01 . If any other PCM DTCs are
retrieved, REFER to Section 303-14 .
B3 CHECK FOR AN AIRFLOW
OBSTRUCTION
Yes
Check the radiator or A/C condenser for REMOVE the obstruction. TEST the system for
an obstruction such as leaves or cardboard. normal operation.
Is an obstruction present?
No
GO to B4 .
B4 CHECK THE ENGINE COOLANT
LEVEL
Yes
NOTE: Allow the engine to cool before GO to B5 .
checking the coolant level.
No
Ignition OFF. ADJUST the engine coolant level as necessary.GO
Visually check the engine coolant level in to B5 .
the coolant expansion tank.
Is the engine coolant level within
specification?
B5 PRESSURE TEST THE ENGINE
COOLING SYSTEM
Yes
Pressure test the engine cooling system. REPAIR or INSTALL new components. TEST the
Refer to Component Tests, Cooling system for normal operation.
System Pressure Test in this section.
Does the engine cooling system leak No
externally? GO to B6 .
B6 CHECK THE PRESSURE RELIEF CAP
Yes
Carry out the Pressure Relief Cap Pressure GO to B7 .
Test. Refer to Component Test, Pressure
Relief Cap Pressure Test in this section. No
Is the pressure relief cap OK? INSTALL a new pressure relief cap. TEST the
B7 CHECK THE ENGINE COOLANT FOR
AN INTERNAL LEAK
PINPOINT TEST B: THE ENGINE OVERHEATS 1541

Inspect the engine coolant in the coolant Yes

expansion tank and the radiator for signs If engine oil is evident, GO to Section 303-00 for
of engine oil or transmission fluid. engine diagnosis. If transmission fluid is evident,
Is engine oil or transmission fluid INSTALL a new radiator. REPAIR the transmission
evident in the coolant? as necessary. Refer to the appropriate section in
Group 307 for the procedure. TEST the system for
normal operation.
No
GO to B8 .
B8 CHECK THE ENGINE OIL AND
TRANSMISSION FLUID FOR COOLANT
Yes
Remove the oil level indicators from the If coolant is in the engine oil, GO to Section 303-00 .
engine and the transmission. If coolant is in the transmission fluid, INSTALL a
Is coolant evident in the oil or new radiator. REPAIR the transmission as necessary.
transmission fluid? Refer to the appropriate section in Group 307 for the
procedure.
No
GO to B9 .
B9 CHECK THE COOLING SYSTEM FOR
COMBUSTION GASES
Yes
NOTE: Use UView Combustion Leak GO to Section 303-00 for engine diagnosis.
Tester part number UVU560000-R or
equivalent. No
Using a cooling system combustion gas GO to B10 .
leak tester, following the instructions
supplied with the tester, check the coolant
for combustion gases.
Are combustion gases present?
B10 CHECK COOLANT CONDITION
Yes
Check the coolant for dirt, rust or GO to B11 .
contamination and check the coolant
concentration. No
Is the coolant condition OK? FLUSH the engine cooling system. REFER to
Cooling System Flushing in this section. TEST the
B11 CHECK THE ELECTRIC COOLING
FAN OPERATION
Yes
Start the engine. GO to B12 .
Place the climate control function selector
in the MAX A/C position and the blower No
motor switch in the HI position. DIAGNOSE the electric cooling fan operation.
Did the electric cooling fan operate? REFER to the Powertrain Control/Emissions
B12 CHECK THE COOLANT PUMP
OPERATION
PINPOINT TEST B: THE ENGINE OVERHEATS 1542

Start the engine. Yes

Allow the engine to run for 10 minutes. GO to B13 .
Place the climate control function selector
in the MAX HEAT position. Feel the No
heater outlet hose. INSTALL a new coolant pump. TEST the system for
Is the heater outlet hose hot? normal operation.
B13 CHECK THE THERMOSTAT
OPERATION
Yes
Start the engine. CHECK the engine coolant temperature gauge
Allow the engine to run for 10 minutes. operation. REFER to Section 413-01 .
Feel the upper radiator hose.
Is the upper radiator hose hot? No
GO to B14 .
B14 VISUALLY INSPECT THE
THERMOSTAT
Yes
Carry out the Thermostat Visual INSTALL a new thermostat. TEST the system for
Inspection in the Component Tests portion normal operation.
of this section.
Is the thermostat damaged? No
INSTALL a new thermostat. TEST the system for
normal operation. If the engine still overheats,
INSTALL a new radiator. TEST the system for
normal operation.
Pinpoint Test C: The Engine Does Not Reach Normal Operating Temperature
Normal Operation
The engine cooling system maintains engine temperatures during operation. Correct coolant flow through the
engine, radiator and remainder of cooling system passages and components is essential to maintaining a
correct engine temperature.
Concerns of engine inability to reach normal operating temperature typically occur when the rate of coolant
flow through some coolant circuits (radiator, heater core) is more than expected given the conditions or the
electric cooling fan is always on. Heat is not allowed to build in the engine because a heat exchanger is
removing too much heat, including the radiator and heater core. In addition, perceived concerns that the
engine does not reach normal operating temperature can be related to a low coolant level or trapped air which
does not allow for hot coolant to be available at the heater core, an inoperative climate control system, or for
concerns perceived or related to an incorrect engine temperature gauge indication.
DTC P0125 (Insufficient Coolant Temperature For Closed Loop Fuel Control) Indicates the
Cylinder Head Temperature (CHT) sensor has not achieved the required temperature level to enter
closed loop operating conditions within a specified amount of time after starting the engine.
DTC P0128 (Coolant Thermostat [Coolant Temperature Below Thermostat Regulating Temperature])

Indicates that the thermostat monitor has not achieved the required engine operating temperature
within a specified amount of time after starting the engine.

Low coolant level
Thermostat
Engine Coolant Temperature (ECT) gauge
Electric cooling fan
PINPOINT TEST C: THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE

C1 CARRY OUT
INSPECTION AND
VERIFICATION
Yes
Carry out the REPAIR as needed. TEST the system for normal operation.
inspection and
verification No
procedure in this GO to C2 .
section.
Were any
concerns found?
C2 CHECK FOR DTC
P0125 or P0128
Yes
Check for DTC GO to C3 .
P0125 or P0128.
Is DTC P0125 or No
P0128 present? The cooling system is operational. If an inoperative engine coolant
temperature gauge is suspected, CHECK the engine coolant temperature
gauge operation. REFER to Section 413-01 . If an inoperative climate
control system is suspected, CHECK the climate control system operation.
REFER to Section 412-00 . If any other PCM DTCs are retrieved, REFER to
Section 303-14 .
C3 CHECK THE
ELECTRIC COOLING
FAN OPERATION
Yes
Allow the engine DIAGNOSE the electric cooling fan operation. REFER to the Powertrain
to cool. Control/Emissions Diagnosis (PC/ED) manual.
Make sure the A/C
switch is OFF. No
Start the engine. GO to C4 .
Check the electric
cooling fan.
1544
Is the electric
cooling fan on all
the time?
C4 CHECK THE
COOLANT LEVEL
Yes
NOTE: Allow the INSTALL a new thermostat. TEST the system for normal operation.
engine to cool
before checking No
the coolant level. GO to Pinpoint Test A to diagnose a coolant leak.
Visually check the
engine coolant
level in the coolant
expansion tank.
Is the engine
coolant level
within
specification?
Component Tests
Coolant System Pressure Test
1. Turn the engine OFF.
2. Remove the pressure relief cap. Fill the radiator with coolant if needed.
3. Fit the Radiator Tester to the radiator fill neck.
4. NOTICE: Do not pressurize the cooling system beyond the maximum pressure listed in the
specifications table in this section, or cooling system components can be damaged.
NOTE: If the plunger of the pressure tester is pressed too fast, an erroneous pressure reading will
result.
Slowly press the plunger of the pressure test pump to the maximum allowed pressure and hold for 2
minutes. If the pressure drops within this time, inspect for leaks and repair as necessary.
5. If no leaks are found and the pressure drops, the leak may be internal to the radiator transmission
cooler. Inspect the coolant for transmission fluid and the transmission fluid for coolant. Repair as
1545
necessary.
6. If there is no contamination of the coolant or transmission fluid, the leak may be internal to the
engine. Inspect the coolant for engine oil and the engine oil for coolant. Refer to Section 303-00 to
diagnose the engine.
Cap
1. Inspect the pressure relief cap and seals for damage or deterioration. Install a new pressure relief cap
if necessary.
2. Fit the pressure relief cap to the Pressure Test Kit using the correct adapter.
3. NOTE: If the plunger of the pressure tester is pressed to fast, an incorrect pressure reading will result.
Slowly pump the Pressure Test Kit until the pressure gauge stops increasing and note the highest
pressure reading. Release the pressure and repeat the test. Install a new pressure relief cap if the
pressure is not within the pressure listed in the specification table in this section.
Thermostat
A new thermostat should be installed only after the following tests and checks have been carried out:
Pinpoint Test A, B or C
Thermostat Visual Inspection
Thermostat Visual Inspection
1. Remove the thermostat.
2. Examine the thermostat for signs of damage including:

Valve not fully seated (light visible through the valve)
Foreign material lodged in the main valve
Bent or broken frame or flange
Bent or broken spring
Bent or broken valve or valve stem
Wax leaking from wax reservoir or a bulge in the reservoir
Any other damage or distortion
3. NOTE: If no damage is found during the inspection, do not attempt to open the thermostat using hot
water or other heat sources. This method is not an accurate means to test the function of the
thermostat and may damage the thermostat.
If damage is found during the inspection, remove any foreign material or broken pieces and install a
new thermostat.
4. If no damage is found during the inspection, continue troubleshooting the system concern. Go to the
Symptom Chart for further instructions.
Radiator Leak Test, Removed From Vehicle
NOTICE: Never leak test an aluminum radiator in the same water that copper/brass radiators are
1546
tested in. Flux and caustic cleaners may be present in the cleaning tank and they will damage aluminum
radiators.
NOTE: Always install plugs in the transmission fluid cooler fittings before leak testing or cleaning any
radiator.
NOTE: Clean the radiator before leak testing to avoid contamination of tank.
Leak test the radiator in clean water with pressurized air to the maximum pressure listed in the Specifications.
1547

Cooling System Draining, Filling and Bleeding
Special Tool(s)
Airlift Cooling System Tester

UVU550000 or equivalent
Material
Item Specification
Engine Coolant
Draining
NOTICE: Always fill the cooling system with the manufacturer's specified coolant. If a non-specified
coolant has been used the cooling system must be chemically flushed. Refer to Cooling System Flushing
in this section. Failure to follow these instructions may damage the engine or cooling system.
NOTICE: The coolant mut be recovered in a suitable, clean container for reuse. If the coolant is
contaminated it must be recycled or disposed of correctly and the cooling system chemically flushed
and filled with new coolant. Failure to follow these instructions may damage the engine or cooling
system.
NOTE: Less than 80% of the coolant capacity can be recovered with the engine in the vehicle. Dirty, rusty or
contaminated coolant requires replacement.
100-02 .
2. Make sure the engine is cool.
3. Wrap a thick cloth around the radiator cap. Slowly turn the cap counterclockwise until the pressure
begins to release.
4. Step back while the pressure releases.
5. When sure all the pressure has been released, use the cloth to turn and remove the cap.
6. Place a suitable container below the radiator draincock. Drain the coolant.
Tighten the radiator draincock when finished.
Cooling System Draining, Filling and Bleeding 1548

Filling and Bleeding with a Vacuum Cooling System Filler
NOTICE: Vehicle cooling systems are filled with Motorcraft Specialty Orange Engine Coolant.
Always fill the cooling system with the manufacturer's specified coolant. If a non-specified coolant has
been used the cooling system must be chemically flushed. Refer to Cooling System Flushing in this
section. Failure to follow these instructions may damage the engine or cooling system.
coolant must be maintained at the correct concentration and fluid level. Failure to follow these
instructions may result in engine or cooling system damage.
Do not mix coolant types. Mixing coolants may degrade the coolant's corrosion protection.
Do not add alcohol, methanol or brine, or any engine coolants mixed with alcohol or methanol
Do not mix with recycled coolant. Use of such coolant may harm the engine and cooling system
components.
1. Connect the Airlift Cooling System Tester body and the appropriate rubber adapter to the radiator.
2. Clamp the radiator-to-coolant expansion tank hose near the radiator.
3. Follow the Airlift Cooling System Tester manufacturer's instructions to fill and bleed the cooling
system.
Recommended coolant concentration is 50/50 engine coolant to distilled water.
For extremely cold climates (less than -37C [-34F]):
It may be necessary to increase the coolant concentration above 50%.
NEVER increase the coolant concentration above 60%.

A coolant concentration of 60% provides freeze point protection down to -50C

(-58F).
Engine coolant concentration above 60% decreases the overheat protection
characteristics of the engine coolant and may damage the engine.
For extremely hot climates:
It is still necessary to maintain the coolant concentration above 40%.
NEVER decrease the coolant concentration below 40%.
(-15F).
Engine coolant concentration below 40% decreases the corrosion and freeze
protection characteristics of the engine coolant and may damage the engine.
Vehicles driven year-round in non-extreme climates should use a 50/50 mixture of engine
coolant and distilled water for optimum cooling system and engine protection.
Filling and Bleeding without a Vacuum Cooling System Filler
NOTICE: Vehicle cooling systemfilled with Motorcraft Specialty Orange Engine Coolant. Always fill
the cooling system with the manufacturer's specified coolant. If a non-specified coolant has been used
the cooling system must be chemically flushed. Refer to Cooling System Flushing in this section. Failure
to follow these instructions may damage the engine or cooling system.
coolant must be maintained at the correct concentration and fluid level. Failure to follow these
instructions may result in engine or cooling system damage.
Do not mix coolant types. Mixing coolants may degrade the coolant's corrosion protection.
Do not add alcohol, methanol or brine, or any engine coolants mixed with alcohol or methanol
Do not mix with recycled coolant. Use of such coolant may harm the engine and cooling system
components.
1. Fill the radiator through the radiator fill neck until the coolant level is at the bottom of the filler neck.
Recommended coolant concentration is 50/50 engine coolant to distilled water.
For extremely cold climates (less than -37C [-34F]):
It may be necessary to increase the coolant concentration above 50%.
NEVER increase the coolant concentration above 60%. i>
(-58F).
Engine coolant concentration above 60% decreases the overheat protection
characteristics of the engine coolant and may damage the engine.
For extremely hot climates:
It is still necessary to maintain the coolant concentration above 40%.
NEVER decrease the coolant concentration below 40%.
(-15F).
Engine coolant concentration below 40% decreases the corrosion and freeze
protection characteristics of the engine coolant and may damage the engine.

Vehicles driven year-round in non-extreme climates should use a 50/50 mixture of engine
coolant and distilled water for optimum cooling system and engine protection.
2. Install the radiator cap.
3. Fill the coolant expansion tank until the coolant reaches the COLD FILL mark.
4. On the Electronic Manual Temperature Control (EMTC), move the temperature blend selector to the
full WARM position. On the Electronic Automatic Temperature Control (EATC), set the temperature
to 32C (90F).
5. NOTICE: If the air discharge remains cool and the engine coolant temperature gauge does not
move, the engine coolant level is low in the engine and must be filled. Stop the engine, allow it to
cool and fill the cooling system. Failure to follow this instructions may result in damage to the
engine. p>Run the engine at idle until it reaches normal operating temperature.
6. Add more correct coolant mixture to the coolant expansion tank until the coolant level is at the COLD
FILL mark.
7. Turn the engine off and allow it to cool.
8. Start the engine and allow it to idle until it reaches normal operating temperature. While the engine is
idling, feel for hot air from the A/C vents.
Hot air should discharge from the A/C vents. The engine coolant temperature gauge should
maintain a stabilized reading in the middle of the NORMAL range and the upper radiator
hose should feel hot to the touch.
9. Check the engine coolant level in the coolant expansion tank and fill it as necessary.
10. Repeat the previous 5 steps as necessary.


Cooling System Flushing
Material
Item Specification
Motorcraft Premium Cooling ESR-M14P7-A
System Flush
VC-1
1. WARNING: Always allow the engine to cool before opening the cooling system. Do not
unscrew the coolant pressure relief cap when the engine is operating or the cooling system is
hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when
the cap is loosened slightly. Failure to follow these instructions may result in serious personal
injury.
Drain the engine cooling system. For additional information, refer to Cooling System Draining,
Filling and Bleeding in this section.
2. Remove the thermostat.
3. Install the thermostat housing without the thermostat.
4. NOTE: Refer to the cooling system flusher manufacturer's operating instructions for specific vehicle
hook-up.
Use a cooling system flusher to flush the engine and radiator.

Use Premium Cooling System Flush.
5. Install the thermostat.
6. Fill and bleed the cooling system. For additional information, refer to Cooling System Draining,
Cooling System Flushing 1552

Cooling System Flushing 1553


Block Heater
Material
Item Specification
Engine Coolant

1 14A199 Block heater electrical connector
2 - Block heater retaining screw (part of 6A051)
3 6A051 Block heater
1. Drain the engine cooling system. For additional information, refer to Cooling System Draining,
2. NOTE: Do not loosen the block heater retaining screw more than necessary for removal.
Loosen the block heater retaining screw and remove the block heater.
3. NOTICE: Route the block heater power cable away from hot or rotating components, or
damage to the cable can occur.
NOTE: Lubricate the block heater O-ring seal with clean engine coolant prior to installation.
Block Heater 1554

Block Heater 1555


Coolant Crossover Manifold Assembly
1. The coolant crossover manifold assembly is serviced with the intake manifold. For additional
Coolant Crossover Manifold Assembly 1556


Thermostat and Thermostat Housing
Material
Item Specification
ZC-31-A
ZC-30

1 15161 Upper radiator hose clamp
3 W503279 Thermostat housing bolts (2 required)
5 N806807 Thermostat O-ring seal
6 8575 Thermostat
2. If servicing the thermostat housing, disconnect the upper radiator hose from the thermostat housing.
3. Remove the 2 bolts, the thermostat housing and the thermostat. Discard the O-ring seal.
Inspect the mating surfaces. Clean the sealing surfaces with metal surface prep and silicone
gasket remover. Folle directions on the packaging.
If necessary, install a new thermostat with the spring facing down.
Install a new O-ring seal.
NOTE: Make sure the thermostat housing is seated evenly by hand tightening the 2
thermostat housing bolts prior to final tightening.
Thermostat and Thermostat Housing 1557

Thermostat and Thermostat Housing 1558


Coolant Pump
Material
Item Specification
ZC-31-A
Engine Coolant

2 8A528 Coolant pump pulley
3 N808794 Coolant pump bolt (4 required)
4 8501 Coolant pump
5 391108 Coolant pump O-ring seal
Removal
2. Loosen the 4 coolant pump pulley bolts.
3. Remove the accessory drive belt. For additional information, refer to Section 303-05 .
4. Remove the 4 bolts and the coolant pump pulley.
5. Remove the 4 bolts and the coolant pump. Discard the O-ring seal.
6. Inspect the sealing surfaces and clean with metal surface prep. Follow the directions on the
packaging.
Installation
Coolant Pump 1559

1. NOTICE: Align the bolt holes with the bosses prior to insertion of the coolant pump and insert
the pump straight into the coolant pump cavity. Do not rotate the coolant pump once installed
in the coolant pump cavity or damage to the O-ring seal can occur, causing the coolant pump to
leak.
NOTE: Install a new O-ring seal and lubricate with clean engine coolant.
Install the coolant pump and 4 bolts.
2. Install the coolant pump pulley and 4 bolts.
3. Install the accessory drive belt. For additional information, refer to Section 303-05 .
4. Tighten the 4 bolts for the coolant pump pulley.

5. Fill and bleed the engine cooling system. For addition information, refer to Cooling System Draining,
Coolant Pump 1560


Cooling Module
Special Tool(s)
Disconnect Tool, Transmission Cooler Line

307-569

1 W705764 Battery power cable nut
2 Battery power cable terminal (part of 12A581)
3 Battery Junction Box (BJB) (part of 12A581)
4 Wiring harness retainer (part of 12A581)
5 W710897 Power steering fluid reservoir stud bolt
6 3E764 Power steering fluid reservoir
7 Power steering fluid cooler hose retainer (part of
3A713)
Cooling Module 1561


1 Wiring harness retainer (part of 14305)
2 Electrical connector retainer (part of 12A581)
Cooling Module 1562


2 Upper radiator hose retainer (part of 8B274)
3 Wiring harness retainer (part of 12A581) (3 required)
Part
1 Cooling fan electrical connector (part of 12A581) (2
required)
2 Cooling fan wiring harness retainer (part of 12A581) (3
required)
Cooling Module 1563


1 W500110 Condenser inlet fitting bolt
2 W520413 Condenser outlet fitting nut
3 19E558 Condenser inlet jumper line fitting
4 Condenser outlet fitting (part of 19A834)
5 19B596 O-ring seal and gasket seal kit (2 required)

1 8N029 Radiator overflow hose
4 8B365 Lower radiator hose spring clip
Cooling Module 1564

Part
1 16B975 Hood latch assembly cable retainer
2 W711848 Hood latch assembly bolts (2 required)
3 6100 Hood latch assembly
4 7J801 Transmission fluid cooler tube secondary latch (2
required)
5 7H420 Transmission fluid cooler tube (2 required)
6 Power steering fluid cooler hose clamp (2 required)
7 3A713 Power steering gear-to-fluid cooler return hose
8 3B726 Power steering fluid cooler supply hose
9 W701835 Cooling module upper bolt (2 required)
10 W701835 Cooling module front bolt (4 required)
Removal
100-02 .
3. Recover the A/C system refrigerant. For additional information, refer to Section 412-00 .
5. Remove the RH and LH headlamp assemblies. For additional information, refer to Section 417-01 .
Cooling Module 1565

7. Release the 2 clamps and disconnect the 2 power steering fluid cooler hoses from the condenser core.
8. Release the 2 tabs and open the Battery Junction Box (BJB) cover. Remove the battery power cable
nut and disconnect the battery power cable terminal.
9. Release the clamp and disconnect the upper radiator hose from the radiator. Detach the radiator hose
retainer from the cooling fan motor and shroud.
10. Detach the wiring harness retainer from the top RH side of the radiator.
11. Detach the electrical connector retainer and the wiring harness retainer from the top RH side of the
cooling fan motor and shroud.
12. Detach the 3 wiring harness retainers from the RH side of the cooling fan motor and shroud.
13. Detach the power steering fluid cooler hose from the LH side of the cooling fan motor and shroud.
14. Detach the wiring harness retainer from the power steering fluid reservoir stud bolt.
15. Detach the wiring harness retainer from the LH side of the cooling fan motor and shroud.
16. Remove the power steering fluid cooler stud bolt.
17. Disconnect the 2 cooling fan electrical connectors and detach the 3 cooling fan wiring retainers from
the cooling fan motor and shroud.
18. Release the 4 BJB retaining tabs and detach the BJB from the bracket. Position the BJB , the wiring
harness and the power steering fluid reservoir aside.
19. Remove the spring clip and disconnect the lower radiator hose from the radiator.
20. Remove the 2 hood latch assembly bolts.
21. Disconnect the 2 cable position retainers and position the hood latch assembly aside.
22. Remove the pushpin and move the air deflector aside.
Cooling Module 1566

23. Remove the 2 transmission cooler tube secondary latches.
24. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes
from the transmission fluid cooler hoses.
25. Remove the condenser inlet fitting bolt, the condenser outlet fitting nut and disconnect the 2 fittings.
Discard the O-ring and gasket seals.
26. Disconnect the horn assembly electrical connector.
27. Disconnect the ambient temperature sensor electrical connector.
28. Remove the 6 cooling module bolts and remove the cooling module from the vehicle.
Installation
1. Position the cooling module in the vehicle.
2. Install the 6 cooling module bolts.

3. Connect the ambient temperature sensor electrical connector.
Cooling Module 1567

4. Connect the horn assembly electrical connector.
5. Using new O-ring seals and gaskets, connect the A/C condenser outlet and inlet fittings and install the
nut and bolt.
6. Connect the transmission fluid cooler tubes and install the 2 secondary latches.
7. Position the air deflector and install the pushpin.
8. Position the hood latch assembly and install the 2 hood latch assembly bolts.
9. Connect the 2 hood latch cable position retainers.
10. Connect the lower radiator hose to the radiator and install the spring clip.
Cooling Module 1568

11. Position the wiring harness, the BJB and the power steering fluid reservoir. Attach the BJB to the
bracket.
12. Install the power steering fluid reservoir stud bolt.

13. Attach the wiring harness retainer to the power steering fluid reservoir stud bolt.
14. Attach the power steering fluid cooler hose to the LH side of the cooling fan motor and shroud.
15. Attach the wiring harness retainer to the LH side of the cooing fan motor and shroud.
16. Attach the 3 cooling fan wiring harness retainers to the cooling fan and connect the 2 cooling fan
electrical connectors.
17. Attach the 3 wiring harness retainers to the RH side of the cooling fan motor and shroud.
18. Attach the wiring harness retainer and the electrical connector retainer to the top RH side of the
19. Attach the wiring harness retainer to the top RH side of the radiator.
20. Connect the upper radiator hose to the radiator and position the clamp. Attach the upper radiator hose
retainer to the cooling fan motor and shroud.
21. Connect the battery power cable terminal and install the nut. Close the BJB cover.
22. Connect the 2 power steering fluid cooler hoses to the condenser core and position the clamps.
23. Install the front bumper cover. For additional information, refer to Section 501-19 .
24. Install the RH and LH headlamp assemblies. For additional information, refer to Section 417-01 .
26. Fill and bleed the engine cooling system. For additional information, refer to Cooling System
Draining, Filling and Bleeding in this section.
27. Fill and bleed the power steering system. For additional information, refer to Section 211-00 .
28. Fill the transmission with fluid and verify correct operation. For additional information, refer to
Section 307-01 .
29. Evacuate, leak test and charge the refrigerant system. For additional information, refer Section 412-00
.
Cooling Module 1569

Cooling Module 1570


Radiator

1 8075 Radiator overflow hose
2 8260 Upper radiator hose
3 8286 Lower radiator hose
4 8B365 Lower radiator hose spring clip

1 W503924 Radiator bolt (2 required)
2 7C410 Transmission fluid cooler-to-radiator upper hose
3 7B028 Transmission fluid cooler-to-radiator lower hose
4 8005 Radiator
Radiator 1571
5 8124 Radiator insulator (2 required)

100-02 .
2. Drain the cooling ssytem. For additional information, refer to Cooling System Draining, Filling and
Bleeding in this section.
3. Remove the RH and LH headlamp assemblies. For additional information, refer to Section 417-01 .
4. Remove the cooling fan motor and shroud. For additional information, refer to Cooling Fan Motor
and Shroud in this section.
5. Disconnect the radiator overflow hose from the radiator.
6. Release the clamp and disconnect the upper radiator hose from the radiator.
7. Remove the spring clip and disconnect the lower radiator hose from the radiator.
8. Remove the 2 radiator bolts.

9. Remove the 2 bolts and position the coolant expansion tank aside.
10. Disconnect the electrical connector and remove the bolt and the horn assembly.
Remove the 6 LH and RH air deflector-to-condenser core pin-type retainers.
Radiator 1572
12. Disconnect the 2 transmission fluid cooler-to-radiator hoses.
13. NOTE: The cooling module must be positioned rearward to raise and detach the 4 condenser mounts
from the radiator.
Depress the retaining tabs on the 2 lower condenser mounting brackets and raise the condenser
assembly until the 4 condenser mounting brackets detach from the radiator.
14. Remove the radiator.
17. Carry out the transmission fluid level check. For additional information, refer to Section 307-01 .
Radiator 1573

Cooling Fan Motor and Shroud

1 W705764 Battery power cable nut
2 - Battery power cable terminal (part of 12A581)
3 W711851 Battery Junction Box (BJB) bracket bolt (4 required)
4 14A65 BJB bracket
5 - Wiring harness retainer (part of 12A581)
6 W710897 Power steering fluid reservoir stud bolt
7 3E764 Power steering fluid reservoir
8 - Power steering fluid cooler hose retainer (part of
3A713)
Cooling Fan Motor and Shroud 1574


2 - Upper radiator hose retainer (part of 8B274)
3 - Wiring harness retainer (part of 12A581) (3 required)


1 - Wiring harness retainer (part of 14305)
2 - Electrical connector retainer (part of 12A581)
Part
1 - Cooling fan wiring harness retainer (part of 12A581) (3
required)
2 - Cooling fan electrical connector (part of 12A581) (2
required)
3 W503924 Cooling fan motor and shroud bolt (2 required)
4 8600 Cooling fan motor and shroud

2. Remove the upper air deflector.

1. Remove the 12 upper air deflector pushpins.
2. Remove thr deflector.
3. Release the 2 tabs and open the Battery Junction Box (BJB) cover. Remove the battery power cable
nut and disconnect the battery power cable terminal.
4. Remove the air cleaner outlet tube. For additional information, refer to Section 303-12 .
5. Detach the power steering fluid cooler hose retainer from the cooling fan motor and shroud.
6. Detach the wiring harness retainer from the power steering fluid reservoir stud bolt.
7. Detach the wiring harness retainer from the LH side of the cooling fan motor and shroud.
8. Detach the wiring harness retainer from the top RH side of the radiator.
9. Detach the electrical connector retainer and the wiring harness retainer from the top RH side of the
10. Detach the 3 wiring harness retainers from the RH side of the cooling fan motor and shroud.
11. Detach the upper radiator hose retainer from the cooling fan motor and shroud.
12. Disconnect the 2 cooling fan electrical connectors.
13. Detach the 3 cooling fan wiring harness retainers.
14. Remove the 4 BJB bracket bolts.

15. Remove the power steering fluid reservoir stud bolt and position the power steering fluid reservoir
and the wiring harness aside.
16. Remove the 2 bolts and the cooling fan motor and shroud.



Coolant Expansion Tank
Material
Item Specification
Engine Coolant
Part
2 8A080 Coolant expansion tank/lower Air Cleaner (ACL)
housing assembly
3 W701835 Coolant expansion tank bolts (2 required)
1. NOTICE: Allow the engine to cool before removing the coolant expansion tank. The radiator
draws coolant from the coolant expansion tank as the engine cools. If the coolant expansion
tank is removed before the engine cools, the radiator will draw air into the system, resulting in
possible engine damage.
Using a suitable suction device, siphon the coolant from the coolant expansion tank.
2. Remove the Air Cleaner (ACL) element. For additional information, refer to Section 303-12 .
3. Remove the hood sensor and nut.
Coolant Expansion Tank 1579

4. Disconnect the coolant overflow hose from the radiator.
5. Remove the 2 bolts and the coolant expansion tank/lower ACL housing assembly.

Fill the coolant expansion tank with the recommended mixture of coolant and distilled water.
For additional information, refer to Cooling System Draining, Filling and Bleeding in this
section.

SECTION 303-04: Fuel Charging and Controls - 5.4L 2011 Expedition, Navigator Workshop
(3V) Manual
Material

Capacity
Motorcraft SAE 5W-20 Premium WSS-M2C930-A -
Synthetic Blend Motor Oil
XO-5W20-QSP (US); Motorcraft
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada);
or equivalent
Air Cleaner (ACL) outlet pipe-to-Throttle Body (TB) adapter bolts 10 89
Air intake resonator assembly bolt 10 89
Fuel(FP) control module bolts 9 80
Fuel rail bolts 10 89
TB bolts a - -


SECTION 303-04: Fuel Charging and Controls - 5.4L (3V)
Manual
Fuel Charging and Controls
Sequential Multi-Port Fuel Injection (SFI)
The fuel charging and controls system consists of the following:
Throttle Body (TB)

Fuel injectors
Fuel rail
The fuel charging and controls system is:
a Sequential Multi-Port Fuel Injection (SFI) system.

Pulse Width Modulated (PW
Mass Air Flow (MAF) controlled.
Fuel is metered into each intake port in a sequential firing order. Fuel injectors pulse to follow engine firing
order, in accordance with engine demand, on a tuned intake manifold.
The basic fuel requirement of the engine is determined from the data supplied to the PCM by the MAF sensor,
which measures the amount of air being drawn into the engine.
The various sensors detect any changes in the operating conditions and send signals to the PCM. This permits
the PCM to control the opening duration (pulse width) of the fuel injectors and maintain optimum exhaust
emission control and engine performance for all operating conditions.
Throttle Body (TB)
The TB :
controls air supply to the intake manifold by electronically positioning the throttle plate.
is not adjustable.
Refer to Throttle Body in this section.
Fuel Injectors
The fuel injectors:
are electronically operated by the PCM.

atomize the fuel as the fuel is delivered.
each have an internal solenoid that opens a needle valve, which injects fuel into the intake port in the
cylinder head.
Fuel Charging and Controls 1582

are deposit resistant.
For removal and installation, refer to Fuel Rail and Fuel Injector - Exploded View and Fuel Rail in this
section.
Fuel Rail
NOTICE: The fuel injectors and the fuel rail must be handled with extreme care to prevent damage to
sealing areas and sensitive fuel-metering orifices.
The fuel rail:
receives fuel from the fuel supply tube.

delivers fuel to the fuel injectors.
For removal and installation, refer to Fuel Rail and Fuel Injector - Exploded View and Fuel Rail in this
section.


SECTION 303-04: Fuel Charging and Controls - 5.4L (3V)
Manual
Fuel Charging and Controls
For driveability concerns, refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.

(3V) Manual
Throttle Body
Air Cleaner (ACL) Outlet Pipe-to-Throttle Body (TB) Adapter and Air Intake Resonator
Part
3 - Throttle Body (TB) adapter-to-air intake resonator clamp
5 9F991 Air Cleaner (ACL) outlet pipe-to- title="Throttle Body"
class="popup"
onmouseover="this.className='popupnounderline';"
onmouseout="this.className='popup';">TB adapter bolt
(3 required)
7 - ACL outlet pipe-to- TB adapter seal (part of 9A589)
Throttle Body (TB)
Throttle Body 1585

Part
1 - Throttle Position (TP) sensor electrical connector (part
of 12B637)
2 - Electronic Throttle Control (ETC) electrical connector
(part of 12B637)
3 N705438 Throttle Body (TB) bolt (4 required)
4 9J444 Vibration damper
5 9F991 TB
6 9E936 TB O-ring seal
Removal
2. Disconnect the crankcase ventilation tube quick connect coupling from the ACL outlet
pipe-to-Throttle Body (TB) adapter. For additional information, refer to Section 310-00 .
3. Release the clamp and remove the bolt and the air intake resonator assembly.
4. Remove the 3 ACL outlet pipe-to- TB adapter bolts.
5. Remove the ACL outlet pipe-to- TB adapter.
6. Disconnect the Electronic Throttle Control (ETC) electrical connector.
7. Disconnect the Throttle Position (TP) sensor electrical connector.
8. Remove the 4 bolts, the vibration damper and the TB assembly.

Discard the TB O-ring seal.
Installation
Throttle Body (TB) 1586

1. Using a new O-ring seal, position the TB , the vibration damper and tighten the 4 bolts in 2 stages.
Stage 2: Tighten an additional 90 degrees (one-fourth turn).
2. Connect the TP sensor electrical connector.
3. Connect the ETC electrical connector.
4. Position the ACL outlet pipe-to- TB adapter.
5. Install the 3 ACL outlet pipe-to- TB adapter bolts.

7. Connect the crankcase ventilation tube quick connect coupling to the ACL outlet pipe-to- TB adapter.
8. Install the ACL outlet pipe. For additional information, refer to Section 303-12 .
Throttle Body (TB) 1587

(3V) Manual
Fuel Rail and Fuel Injector - Exploded View
Air Cleaner (ACL) Outlet Pipe-to-Throttle Body (TB) Adapter, Air Intake Resonator and PCV Tube
Part
3 - Throttle Body (TB) adapter-to-air intake resonator
clamp
5 W505426 Air Cleaner (ACL) outlet pipe-to- TB adapter bolt (3
required)
7 - ACL outlet pipe-to- TB adapter seal (part of 9A589)
8 6K817 PCV tube
9 9D446 Evaporative Emission (EVAP) tube quick connect
coupling
10 - Throttle Position (TP) sensor electrical connector (part
of 12B637)
11 -
Fuel Rail and Fuel Injector - Exploded View 1588

Electronic Throttle Control (ETC) electrical connector

(part of 12B637)
Fuel Rail and Fuel Injectors
Part
1 14A464 Fuel injector electrical connector (part of 12B637) (8
required)
2
3 9F792 Fuel rail
4 9C995 Fuel injector-to-fuel rail locking clip (8 required)
5 9229 Fuel injector-to-fuel rail O-ring (8 required)
6 9F593 Fuel injector (8 required)
7 9229 Fuel injector-to-intake manifold O-ring (8 required)
Air Cleaner (ACL) Outlet Pipe-to-Throttle Body (TB) Adapter, Air Intake Resonator and PCV Tube
1589
Fuel Rail and Fuel Injectors 1590

(3V) Manual
Fuel Rail
Material
Item Specification
or equivalent
NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is
therefore essential that absolute cleanliness is observed when working with these components. Always
install blanking plugs to any open orifices or tubes.
NOTICE: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove
any foreign material from the connector retaining clip area before separating from the tube.
3. Disconnect the crankcase ventilation tube quick connect coupling from the ACL outlet
pipe-to-Throttle Body (TB) adapter. For additional information, refer to Section 310-00 .
5. Remove the 3 ACL outlet pipe-to- TB adapter bolts.

6. Remove the ACL outlet pipe-to- TB adapter.
7. Disconnect the Electronic Throttle Control (ETC) electrical connector.
8. Disconnect the Throttle Position (TP) sensor electrical connector.
Fuel Rail 1591

9. Disconnect the Evaporative Emission (EVAP) tube quick connect coupling from the intake manifold.
10. Disconnect the fuel tube quick connect coupling. For additional information, refer to Section 310-00 .
11. Disconnect the 8 fuel injector electrical connectors.
12. Remove the 4 fuel rail bolts and the fuel rail and injectors as an assembly.
13. NOTICE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary
O-rings can cause the fuel system to leak.
NOTE: Lubricate the new O-ring seals with clean engine oil prior to installation.
Remove the fuel injector-to-fuel rail locks and separate the 8 fuel injectors from the fuel rail.
Discard the upper and lower fuel injector O-ring seals.
Fuel Rail 1592

(3V) Manual
Fuel Injector
1. The fuel injectors are serviced with the fuel rail. For additional information, refer to Fuel Rail and
Fuel Injector - Exploded View and Fuel Rail in this section.
Fuel Injector 1593

(3V) Manual
Fuel Pump Control Module
Part
1 14A464 Fuel Pump (FP) control module electrical connector
(part of 14404)
2 W705549 FP
3 9345 FP control module
1. Disconnect the Fuel Pump (FP) control module electrical connector.
2. Remove the 2 bolts and the FP control module.

Fuel Pump Control Module 1594


SECTION 303-05: Accessory Drive 2011 Expedition, Navigator Workshop Manual

Item Specification
Accessory drive belt 6 ribs
Description Nm lb-ft
Accessory drive belt idler pulley bolt 25 18
Accessory drive belt tensioner bolts 25 18


Accessory Drive
The accessory drive system:
has a single serpentine drive belt (6 ribs).

has 3 idler pulleys.
has an automatic belt tensioner.
is not adjustable.
The accessory drive system provides power to operate components which power other systems. These could
include components such as the generator, power steering pump and A/C compressor. Each of these
components is equipped with a pulley which is driven by the accessory drive belt. The accessory drive belt is
driven by the engine crankshaft pulley. One or more idler pulleys may be provided to facilitate belt routing
and alignment. The automatic belt tensioner maintains correct belt tension and compensates for component
wear and changes in system load. System load changes can be caused by the A/C compressor clutch engaging
or disengaging, or demand changes on other systems powered by the accessory drive belt. To maintain correct
operation of this system, it is critical that the correct length drive belt be installed. The pulleys must also be
correctly aligned and kept clean.
Accessory Drive Belt Routing
Front End Accessory Drive (FEAD) Components

1 19A216 Belt idler pulley
2 10344 Generator pulley
3 8620 Drive belt
4 19A216 Belt idler pulley
5 3A733 Power steering pump pulley
6 6C348 Belt idler pulley
7 8509 Coolant pump pulley
9 6B209 Drive belt tensioner pulley
10 2E884 A/C compressor pulley
Accessory Drive 1597

Front End Accessory Drive (FEAD) Components 1598


Accessory Drive
NOTICE: Under no circumstances should the accessory drive belt, tensioner or pulleys have any fluids
or belt dressing applied to them as damage to the belt material and tensioner damping mechanism may
occur.
2. Visually inspect for obvious signs of mechanical damage.
Mechanical
Drive belt cracking/chunking/wear

Belt/pulley contamination
Incorrect accessory drive belt
Incorrectly routed accessory drive belt
Pulley misalignment or excessive pulley
runout
Loose or mislocated hardware
Incorrectly routed power steering tubes
(rubbing)
Loose accessory drive belt
Damaged pulleys
Tensioner arm misalignment
Belt Tensioner With Belt Length Indicator
NOTE: Belt tensioner is shown in the free-state position against the arm travel stops.
NOTE: 6.2L engine accessory drive belt tensioner shown, other accessory drive belt tensioners similar.
Accessory Drive 1599

Item Description
1 Belt length indicator
2 Acceptable belt installation and wear range
3 Belt replacement range
4 Belt tension relief point
3. Check that the belt length indicator, if equipped, on the belt tensioner is in the acceptable belt
installation and wear range. If the indicator is in the belt replacement range, either an incorrect belt is
installed or the belt is worn beyond the service limit. Install a new belt as necessary.
4. Eliminate all other non-belt related noises that could cause belt misdiagnosis, such as A/C compressor
engagement chirp, A/C slugging noise, power steering cavitations at low temperatures, Variable
Camshaft Timing (VCT) tick or generator whine.
5. If a concern is found, correct the condition before proceeding to the next step.
V-Ribbed Serpentine Drive Belt With Cracks Across Ribs
6. Check the belt for cracks. Up to 15 cracks in a rib over a distance of 100 mm (4.0 in) can be
considered acceptable. If cracks exceed this standard, install a new belt.
V-Ribbed Serpentine Belt With Piling
NOTE: Piling is an excessive buildup in the V-grooves of the belt.
Belt Tensioner With Belt Length Indicator 1600

7. The condition of the V-ribbed drive belt should be compared against the illustration and appropriate
action taken.
1. Small scattered deposits of rubber material. This is not a concern, therefore, installation of a
new belt is not required.
2. Longer deposit areas building up to 50% of the rib height. This is not considered a durability
concern, but it can result in excessive noise. If noise is apparent, install a new belt.
3. Heavy deposits building up along the grooves resulting in a possible noise and belt stability
concern. If heavy deposits are apparent, install a new belt.
V-Ribbed Serpentine Belt With Chunks of Rib Missing
8. There should be no chunks missing from the belt ribs. If the belt shows any evidence of this, install a
new accessory drive belt.
9. If the concern is not visually evident, verify the symptom and GO to Symptom Chart .
Symptom Chart
Symptom Chart
Component Tests
Drive Belt - Noise/Flutter
NOTICE: Under no circumstances should the accessory drive belt, tensioner or pulleys have any fluids
or belt dressing applied to them as damage to the belt material and tensioner damping mechanism may
occur.
V-Ribbed Serpentine Belt With Piling 1601

Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a
damaged or incorrectly aligned grooved pulley.
To correct, determine the area where the noise comes from. Check each of the pulleys in that area with a
straightedge to the crankshaft pulley. Look for accessory pulleys out of position in the fore/aft direction or at
an angle to the straightedge.
Drive belt squeal may be an intermittent or constant noise that occurs when the drive belt slips on an
accessory pulley under certain conditions.
A short intermittent squeal may occur during engine start up and shut down or during very rapid engine
acceleration and decelerations, such as:
Wide Open Throttle (WOT) 1-2 and 2-3 shifts or 2-3 and 3-4 back-out shifts on automatic
transmissions.
WOT 1-2 and 2-3 shifts and any combination of rapid downshifting on manual transmissions.
These special short-term transient events are expected, and are due to the higher system inertias required to
meet the electrical and cooling demands on today's vehicle systems. Constant or reoccurring drive belt squeal
can occur:
if the A/C discharge pressure goes above specifications:

the A/C system is overcharged.
the A/C condenser core airflow is blocked.
the A/C anti-slugging strategy executes after a long hot heat sk.
if the A/C off equalized pressure (the common discharged and suction pressure that occurs after
several minutes) exceeds specifications.
if any of the accessories or idler pulley(s) are damaged or have a worn or damaged bearing. All
accessories should be rotatable by hand in the unloaded condition. If not, inspect the accessory.
if there is evidence of fluid contamination on the accessory drive belt. When the drive belt has been
exposed to fluid contamination during vehicle operation, such as leaks from the power steering
system, A/C system or cooling system, clean all pulleys with soap and water, rinse with clean water
and install a new accessory drive belt. If the drive belt has been exposed to fluids in a localized area
during routine vehicle service, such as replacement of hoses or fluids, the drive belt and pulleys
should be washed with soap and water immediately (prior to starting the engine), and rinsed with
clean water.
if the accessory drive belt is too long. A drive belt that is too long will allow the accessory drive belt
tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release
tension to the drive belt. If the accessory drive belt tensioner indicator is outside the normal
installation wear range window, install a new accessory drive belt.
NOTE: The accessory drive belt tensioner arm should rotate freely without binding.
Install a new accessory drive belt tensioner if the drive belt tensioner is worn or damaged.
Drive Belt - Incorrect Installation
NOTICE: Incorrect accessory drive belt installation will cause excessive drive belt wear and may cause
the drive belt to come off the pulleys.
Non-standard accessory drive belts can track differently or incorrectly. If an accessory drive belt tracks
incorrectly, install a new accessory drive belt to avoid performance failu or loss of the drive belt.
V-Ribbed Serpentine Belt With Chunks of Rib Missing 1602

Incorrect Installation
Correct Installation
With the engine running, check accessory drive belt tracking on all pulleys. If the edge of the accessory drive
belt rides beyond the edge of the pulleys, noise and premature wear will occur. Make sure the accessory drive
belt rides correctly on the pulley. If an accessory drive belt tracking condition exists, proceed with the
following:
Visually check the accessory drive belt tensioner for damage and wear, especially the mounting pad
surface and arm alignment. If the accessory drive belt tensioner is not installed correctly, the
mounting surface pad will be out of position. If the tensioner arm is worn, the arm will be out of
alignment. Either of these conditions will result in chirp and squeal noises.
With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the
pulley forward faces) for excessive wobble. Install new components as necessary.
Check all accessories, mounting brackets and the accessory drive belt tensioner for any interference
that would prevent the component from mounting correctly. Correct any interference condition and
recheck the accessory drive belt tracking.
Tighten all accessories, mounting brackets and accessory drive belt tensioner retaining hardware to
specification. Recheck the accessory drive belt tracking.
Belt Tensioner - Mechanical
The only mechanical check that needs to be made is a check for tensioner stick, grab or bind.
1. With the engine off, check routing of the accessory drive belt. Refer to the illustrations under
Accessory Drive in the Description and Operation portion of this section.
2. NOTE: The accessory drive belt tensioner spring is very strong and requires substantial force to
release.
Release the tension on the belt and detach the accessory drive belt from the tensioner. Carry out the
following tests:
Move the tensioner from its relaxed position, through its full stroke and back to the relaxed
position to make sure there is no stick, grab or bind, and to make sure that there is tension on
the tensioner spring.
Incorrect Installation 1603

Rotate the tensioner pulley by hand and check for a binding, contaminated or seized
condition.
Inspect the area surrounding the accessory drive belt tensioner for oil leaks or contamination
and repair any leaks.
3. If the accessory drive belt tensioner does not meet the criteria in the previous step, install a new
tensioner. If the accessory drive belt tensioner meets the criteria in the previous step, proceed to
testing the tensioner dynamically.
4. If the tensioner is saturated with oil and grease internally, install a new tensioner.
Belt Tensioner - Dynam
The accessory drive belt tensioner can be checked dynamically as follows:
1. With the engine running, observe the accessory drive belt tensioner movement. The accessory drive
tensioner should move (respond) when the A/C clutch cycles (if equipped), or when the engine is
accelerated rapidly. If the accessory drive belt tensioner movement is excessive without A/C clutch
cycling or engine acceleration, check belt rideout. Excessive belt rideout (uneven depth of grooves in
the belt) can cause excessive accessory drive belt tensioner movement. Check rideout condition by
installing a new belt. If excessive accessory drive belt tensioner movement still exists, install a new
accessory drive belt tensioner.
Correct Installation 1604


Front End Accessory Drive (FEAD) - Exploded View

3 19A216 Accessory drive belt idler pulley
4 N808920 Accessory drive belt tensioner bolt (3 required)
5 6B209 Accessory drive belt tensioner
6 W808102 Accessory drive belt idler pulley bolt
7 6C348 Accessory drive belt idler pulley
9 19A216 Accessory drive belt idler pulley
Front End Accessory Drive (FEAD) - Exploded View 1605

Front End Accessory Drive (FEAD) - Exploded View 1606


Accessory Drive Belt
1. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt.
2. NOTE: Make sure the drive belt is correctly installed on each pulley.
Refer to Accessory Drive in Description and Operation for drive belt routing.
Accessory Drive Belt 1607


Accessory Drive Belt Tensioner
1. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from the A/C
compressor pulley.

Accessory Drive Belt Tensioner 1608


Accessory Drive Belt Idler Pulley
2. Rotate the accessory drive belt tensioner clockwise and position the accessory drive belt aside.
3. Remove the bolt and the accessory drive belt idler pulley.
4. Repeat the previous step for each accessory drive belt idler pulley being serviced.
Accessory Drive Belt Idler Pulley 1609

SECTION 303-06: Starting System 2011 Expedition, Navigator Workshop Manual

Item Specification
Starting System
Normal engine cranking speed 140-220 rpm
Starter motor armature shaft maximum runout 0.11 mm (0.004 in)
Starter motor brush manufactured length 16.8 mm (0.66 in)
Starter motor brush spring tension 18 N (65 oz)
Starter motor commutator maximum runout 0.12 mm (0.005 in)
Starter motor diameter 101.6 mm (4.0 in)
Starter motor maximum load 800 amps
Starter motor minimum stall torque (at 5 volts) 14.7 Nm (10.8 lb-ft)
Starter motor no load current draw 60-80 amps
Starter motor normal load current draw 130-220 amps
Starter circuit maximum voltage drop (engine at normal operating temperature) 0.5 volts

Starter motor ground cable nut 25 18 -
Starter motor mounting bolts 25 18 -
Starter motor mounting stud bolt 25 18 -
Starter solenoid B-terminal nut 12 - 106
Starter solenoid S-terminal nut 5 - 44



Starting System
The starting system consists of the following:
Starter motor
Starter motor relay
Starter drive
Battery
Park/Neutral Position (PNP) switch (integral part of the mechatronics unit)
Ignition switch
PCM
Start diode, part of the One-Touch Integrated Start (OTIS) system
The function of the starting system is to crank the engine at a speed fast enough to permit the engine to start.
When the starter solenoid is energized, a magnetic field is created in the starter solenoid windings. The iron
plunger core is drawn into the starter solenoid coil, and a drive lever and pin connected to the starter drive
engages the drive pinion gear to the flexplate ring gear. When the plunger is pulled all the way in, the contact
disc closes the circuit between the battery and the motor feed terminals. This sends current to the motor and
the drive pinion gear cranks the flexplate to start the engine. When current flows to the starter motor, the
starter solenoid pull-in coil is bypassed, and the hold-in coil keeps the drive pinion gear engaged with the
flexplate.
Automatic transmissions have a PNP switch in the transmission. The PNP switch prevents operation of the
starter motor unless NEUTRAL or PARK is selected.
One-Touch Integrated Start (OTIS)
This vehicle has OTIS , a computer-assisted cranking system. This feature assists in starting the engine. If the
ignition key is turned to the START position and released when the engine begins cranking, the engine may
continue cranking for up to 10 seconds or until the vehicle starts.
Once the ignition is turned to the START position, the PCM reads starter motor request from the ignition
switch and gains control of the starter engagement. The customer is no longer in the loop after the initial crank
request, the customer may release the key to the RUN/START position. The PCM will disengage the starter
motor based on the following events:
The engine is started (rpm threshold)

A set time has been exceeded
The ignition key has been turned to the OFF position
Starting System 1612



Starting System
Special Tool(s)
Flex Probe Kit



Starting System
This vehicle is equipped with a One-Touch Integrated Start (OTIS) starting system. The starting system is
electronically controlled by the PCM. The PCM receives the following inputs:
Brake pedal pressed, from the Brake Pedal Position (BPP) switch, all vehicles
Transmission in PARK or NEUTRAL, from the transmission mechatronics unit
Correctly coded ignition key, from the Passive Anti-Theft System (PATS), vehicles equipped with
PATS
Starter motor request, ignition switch in the START position
When the ignition switch is placed in the START position, voltage is supplied to the coil of the starter relay
through the OTIS diode. A starter motor request signal is also sent to the PCM. If the PCM recognizes the
needed input signals, it provides the starter relay coil with both voltage and a ground. The starter relay
contacts close providing voltage to the starter solenoid, allowing the starter motor to activate. Once the starter
motor begins to crank, the ignition switch may be released. The starter motor will continue to crank until the
engine starts, a PCM controlled crank time has been exceeded or the ignition switch is turned to the OFF
position.
WARNING: Always disconnect the battery ground cable at the battery before disconnecting the
starter motor battery terminal lead. If a tool is shorted at the starter motor battery terminal, the tool
can quickly heat enough to cause a skin burn. Failure to follow this instruction may result in serious
personal injury.
NOTE: The anti-theft system must be functioning correctly before a logical starting system diagnosis can be
carried out. Address anti-theft system concerns before continuing. Refer to Section 419-01B .
1. Verify the customer concern by operating the starting system to duplicate the condition.

2. Remove the accessory drive belt. Refer to Section 303-05 . Verify the crankshaft and each of the
components driven by the accessory drive belt rotate and are not seized or damaged.
3. Inspect to determine if any of the following mechanical or electrical concerns apply.
Flexplate Anti-theft system

Starter Battery
motor Battery Junction Box (BJB) fuse 13
Starter (30A)
motor Smart Junction Box (SJB) fuse 27
bolts (20A)
Damaged wiring harness
Starter relay



418-00 .
If the network test passes, retrieve and record continuous memory DTCs.
10. If the DTCs retrieved are related to the concern, refer to the PCM DTC Chart. For all other DTCs,

DTC Charts
PCM DTC Chart
DTC Description Source Action

P0512 Starter Request PCM CARRY OUT the
Circuit - Ignition Switch
Circuit has Component Test.
Power With the Refer to Wiring
Ignition in the Diagrams Cell 149
OFF Position for component
testing. If
necessary,
REPLACE the
ignition switch. If
the ignition switch
passed the
component test,
REPAIR circuit
CDC35 (BU/WH)
for a short to power.
P0705 Transmission Transmission Refer to the
Range (TR) appropriate section
Sensor Circuit in Group 307 for
Error the procedure.
P1260 Theft Detected, PCM REFER to the DTC P1707 Park/Neutral Transmission Refer to the
Vehicle Chart in Section Position appropriate
Immobilized 419-01B . (PNP) Switch section in
Circuit Group 307
Failure for the
procedure.
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test A: The Engine Does Not Crank
Refer to Wiring Diagrams Cell 20 , Starting System for schematic and connector information.
Normal Operation
Under normal operation, when the ignition switch is turned to the START position and released, the PCM
receives a starter motor request signal through circuit CDC35 (BU/WH), power is then supplied to the starter

relay through circuit CDC38 (WH/VT) from the PCM. The PCM will receive a signal from the transmission
that the vehicle is in PARK or NEUTRAL through circuit CET40 (GN/OG). A ground is supplied through
circuit CDC12 (YE) from the PCM causing the starter relay coil to energize and the relay contacts close. This
allows power to be supplied from Battery Junction Box (BJB) fuse 13 (30A) to the relay contacts which then
flows through circuit CDC25 (BN/GN) to the starter solenoid. The solenoid is grounded at the starter motor.
Energizing the starter solenoid will engage the starter drive into the ring gear and closes the solenoid contacts
allowing power directly from the battery through circuit SDC02 (RD) to the starter motor to start the engine.
The PCM will disengage the starter motor based on engine running (rpm threshold), a set crank time has been
exceeded or the ignition switch has been turned to the OFF position.

Anti-theft system
Battery
Circuitry
Ignition switch
PCM
Park/Neutral Position (PNP) switch (integral to the mechatronics unit)
Start diode
Starter motor
Starter motor relay
PINPOINT TEST A: THE ENGINE DOES NOT CRANK

A1 CHECK THE BATTERY
Yes
Check the battery condition and charge. Refer to Section GO to A2 .
414-01 .
Is the battery OK? No
CHARGE or INSTALL a new
battery as necessary. REFER to
Section 414-01 . TEST the system
A2 CHECK THE PCM FOR DTCs
Yes
Check for PCM DTCs. If PCM DTC P1260 is retrieved,
Were any PCM DTCs retrieved? REFER to Section 419-01B . All
other PCM DTCs, REFER to
Powertrain Control/Emissions
No
GO to A3 .
A3 CHECK THE PCM TR SENSOR PID
Yes
DataLogger - PCM.
While observing the PCM TR sensor PID, place the vehicle No
in PARK and NEUTRAL. REFER to the Park Neutral
Does the PID match the gear selection? Circuit Pinpoint Test to diagnose
the transmission. REFER to
PINPOINT TEST A: THE ENGINE DOES NOT CRANK 1617

Section 307-01 .
A4 CHECK THE BATTERY GROUND CABLE
Yes
Measure the voltage between the positive battery post and the GO to A5 .
battery ground cable connection at the engine.
No
INSTALL a new battery ground
cable. REFER to Section 414-01 .
operation.

A5 CHECK THE STARTER MOTOR GROUND
Yes
Measure the voltage between the positive battery post and the GO to A6 .
starter motor case.
No
CLEAN the starter motor
mounting flange and VERIFY the
starter motor is correctly mounted.
operation.

A6 CHECK THE POWER SUPPLY TO THE STARTER
MOTOR
Yes
Measure the voltage between starter motor C197A-1, circuit GO to A7 .
SDC02 (RD) and ground.
No
INSTALL a new positive battery
cable. REFER to Section 414-01 .
operation.

A7 MANUALLY JUMP THE STARTER MOTOR

Connect one end of a fused jumper wire to starter motor Yes

solenoid terminal C197A-1, circuit SDC02 (RD). GO to A8 .
Momentarily connect the other end of the jumper to starter
motor solenoid terminal C197B-1, circuit CDC25 (BN/GN). No
INSTALL a new starter motor.
REFER to Starter Motor in this
normal operation.
Did the starter motor engage and the engine crank?

A8 CHECK THE START INPUT TO THE STARTER
MOTOR
Yes
Disconnect: Starter S-Connector. CLEAN the starter motor solenoid
Key in START position. S-terminal and connector.
Measure the voltage at the starter motor solenoid S-connector CHECK the wiring and the starter
C197B-1, circuit CDC25 (BN/GN). motor for a loose or intermittent
connection. TEST the system for
normal operation.
No
GO to A9 .
Is the voltage reading greater than 10 volts?

A9 CHECK CIRCUIT CDC25 (BN/GN) FOR AN OPEN
Yes
NOTICE: Use the correct probe adapter(s) when making GO to A10 .
measurements. Failure to use the correct probe
adapter(s) may damage the connector. No
REPAIR circuit CDC25 (BN/GN)
Disconnect: Starter Solenoid S-Connector. for an open. TEST the system for
Measure the resistance of circuit CDC25 (BN/GN) between normal operation.
starter relay pin cavity 5 and the starter solenoid S-connector
C197B-1, circuit CDC25 (BN/GN).
Is the resistance reading 5 ohms or less?

A10 CHECK FOR START INPUT AT THE STARTER

MOTOR RELAY
Yes
GO to A13 .
Disconnect: Starter Motor Relay.
Measure the voltage between starter motor relay pin cavity 1,
circuit CDC38 (WH/VT) and ground with the ignition switch
in the START position.

A11 CHECK THE BATTERY SUPPLY TO THE STARTER
RELAY
Yes
VERIFY the BJB fuse 13 (30A) is
Disconnect: Starter Motor Relay. OK. If OK, REPAIR circuit
Measure the voltage at starter motor relay pin cavity 3. SDC04 (RD). If not OK, REFER
to the Wiring Diagrams manual to
identify the possible causes of the
circuit short.
Is the voltage reading greater than 10 volts?

A12 CHECK FOR STARTER MOTOR RELAY GROUND
Yes
NOTICE: Use the correct probe adapter(s) when making INSTALL a new starter motor
measurements. Failure to use the correct probe relay. TEST the system for
adapter(s) may damage the connector. normal operation.
Disconnect: Starter Motor Relay. No

Key in START position. GO to A20 .
Measure the voltage between starter motor relay pin cavity 1,
circuit CDC38 (WH/VT) and pin cavity 2, circuit CDC12
(YE).


A13 CHECK FOR VOLTAGE ON CIRCUIT CET40 (GN/OG)
AT PCM CONNECTOR
Yes
GO to A14 .
Ignition OFF.
Disconnect: PCM C175B.
Ignition ON.
Measure the voltage between PCM C175B-30, circuit CET40
(GN/OG), harness side and ground while moving the selector
lever from PARK to NEUTRAL.
Is the voltage greater than 10 volts with the selector lever

in PARK and NEUTRAL?
A14 CHECK CIRCUIT CET40 (GN/OG) FOR A SHORT TO
GROUND
Yes
REPAIR circuit CET40 (GN/OG).
Measure the resistance between C175B-30, circuit CET40 TEST the system for normal
(GN/OG), harness side and ground. operation.

A15 CHECK CIRCUIT CET40 (GN/OG) FOR OPEN

Yes
NOTICE: Use the correct probe adapter(s) when making Replace the transmission
measurements. Failure to use the correct probe mechatronics unit. REFER to
adapter(s) may damage the connector. Section 307-01 . TEST the system
Ignition OFF.
Disconnect: Transmission C1548. No
Measure the resistance between PCM C175B-30, circuit REPAIR circuit CET40 (GN/OG).
CET40 (GN/OG), harness side and transmission C1548-10, TEST the system for normal
circuit CET40 (GN/OG), harness side. operation.

A16 CHECK THE START DIODE
Yes
Disconnect: Start Diode. INSTALL a new start diode.
Check the start diode. TEST the system for normal
operation.
No
GO to A17 .
Is the start diode open or shorted?

A17 CHECK CIRCUIT CDC35 (BU/WH) FOR VOLTAGE AT
THE START DIODE
Yes
NOTICE: Use the correct probe adapter(s) when making REPAIR circuit CDC38
measurements. Failure to use the correct probe (WH/VT). TEST the system for
adapter(s) may damage the connector. normal operation.
Disconnect: Start Diode. No

Measure the voltage between start diode cavity C1-60-1, GO to A18 .
circuit CDC35 (BU/WH) and ground with the ignition switch
in the START position.


A18 CHECK CIRCUIT SBP27 (BU/RD) FOR VOLTAGE
Yes
REPAIR circuit SBP27 (BU/RD).
Disconnect: Ignition Switch C250. TEST the system for normal
Measure the voltage between ignition switch C250-9, circuit operation.
SBP27 (BU/RD), harness side and ground.

A19 CHECK THE IGNITION SWITCH
Yes
Carry out the Ignition Switch Component Test. REPAIR circuit CDC35
(BU/WH). TEST the system for
Refer to Wiring Diagrams Cell 149 for component testing. normal operation.
Did the ignition switch pass the component test?
No
INSTALL a new ignition switch.
REFER to Section 211-05 . TEST
A20 CHECK CIRCUIT CDC12 (YE) FOR AN OPEN
Yes
NOTICE: Use the correct probe adapter(s) when making DIAGNOSE the PCM. REFER to
measurements. Failure to use the correct probe the Powertrain Control/Emissions
adapter(s) may damage the connector. Diagnosis (PC/ED) manual.
Disconnect: PCM C175B. No

Measure the resistance between the starter motor relay pin REPAIR circuit CDC12 (YE) for
cavity 2, circuit CDC12 (YE) and PCM C175B-7, circuit an open. TEST the system for
CDC12 (YE). normal operation.

Is the resistance reading 5 ohms or less?
Pinpoint Test B: One-Touch Integrated Start (OTIS) Does Not Operate Correctly
Normal Operation

Circuitry
PCM
PINPOINT TEST B: ONE-TOUCH INTEGRATED START (OTIS) DOES NOT OPERATE CORRECTLY

B1 CHECK THE BATTERY
Yes
Check the battery condition and charge. Refer GO to B2 .
to Section 414-01 .
CHARGE or INSTALL a new battery as
necessary. REFER to Section 414-01 . TEST the
B2 CHECK THE PATS AND PCM FOR DTCs

Check for Passive Anti-Theft System (PATS) Yes

and PCM DTCs. REFER to Section 419-01B to diagnose the PATS
Were any PATS and PCM DTCs DTCs. REFER to Powertrain Control/Emissions
retrieved? Diagnosis (PC/ED) manual to diagnose the PCM
DTCs.
No
GO to B3 .
B3 CHECK THE STATUS OF OTIS
(OTS_STAT) PID
Yes
Enter the following diagnostic mode on the GO to B4 .
scan tool: DataLogger - PCM.
Monitor the PCM PID OTS_STAT with the No
ignition switch in the RUN position. ENABLE OTIS . TEST the system for normal
Is the One-Touch Integrated Start (OTIS) operation. If OTIS will not enable, DIAGNOSE
PID enabled? the PCM. REFER to Powertrain
Control/Emissions Diagnosis (PC/ED) manual.
B4 CHECK THE KEY POSITION FOR START
INDICATED (START_KEY) PID
Yes
Monitor the PCM PID START_KEY with the No
ignition switch in the START position. GO to B5 .
Does the PID change from OFF to ON?
B5 CHECK THE TR SENSOR PID
Yes
While observing the PCM Transmission No
Range (TR) sensor PID, place the vehicle in REFER to the Park Neutral Circuit Pinpoint Test
PARK and NEUTRAL. to diagnose the transmission. REFER to Section
Does the PID match the gear selection? 307-01 .
B6 CHECK CIRCUIT CDC35 (BU/WH) FOR
AN OPEN
Yes
NOTICE: Use the correct probe adapter(s) DIAGNOSE the PCM. REFER to Powertrain
when making measurements. Failure to Control/Emissions Diagnosis (PC/ED) manual.
use the correct probe adapter(s) may
damage the connector. No
REPAIR the circuit CDC35 (BU/WH). TEST the
Ignition OFF. system for normal operation.
Disconnect: PCM C175B.
Disconnect: Start diode.
Measure the resistance between start diode
cell, circuit CDC35 (BU/WH) and PCM
C175B-16, circuit CDC35 (BU/WH), harness
side.
PINPOINT TEST B: ONE-TOUCH INTEGRATED START (OTIS) DOES NOT OPERATE CORRECTLY
1625
Pinpoint Test C: The Engine Cranks Slowly
Normal Operation

Battery
Circuitry
Ground circuit
Starter motor
PINPOINT TEST C: THE ENGINE CRANKS SLOWLY

C1 CHECK THE BATTERY
Yes
Check the battery condition and charge. GO to C2 .
CHARGE or INSTALL a new battery as necessary.
REFER to Section 414-01 . TEST the system for
normal operation.


STARTER
Yes
Measure the voltage between starter motor
terminal C197A-1, circuit SDC02 (RD) No
and ground. REPAIR circuit SDC02 (RD). CLEAN and
TIGHTEN the connections at the battery terminals.
Is the voltage 10 volts or greater?

C3 CHECK MOTOR GROUND CIRCUIT
Yes
Carry out the Motor Ground Circuit Test. INSTALL a new starter motor. TEST the system for
Refer to the Component Tests in this normal operation.
section.
Is the ground OK? No
REPAIR the ground circuit as necessary. TEST the
Pinpoint Test D: Unusual Starter Noise
Normal Operation

Starter motor mounting
Starter motor mounting bolts
Starter motor drive
Flywheel or flexplate ring gear
Starter motor
PINPOINT TEST C: THE ENGINE CRANKS SLOWLY 1627

PINPOINT TEST D: UNUSUAL STARTER NOISE

D1 CHECK THE STARTER MOTOR MOUNTING
Yes
Inspect the starter motor mounting bolts for looseness. GO to D2 .
Is the starter motor mounted correctly?
No
REINSTALL the starter motor correctly.
REFER to Starter Motor in this section.
D2 CHECK FOR ENGINE NOISE
Yes
Connect one end of a fused jumper wire to starter
motor solenoid C197B-1, circuit CDC25 (BN/GN). No
Momentarily connect the other end of the jumper to REFER to Section 303-00 to continue
starter motor C197A-1, circuit SDC02 (RD), engaging the diagnosis.
the starter motor and verify that the noise is due to the
starter operation.
Is the noise due to the starter motor engagement?

D3 CHECK FOR UNUSUAL WEAR
Yes
Remove the starter motor. Refer to Starter Motor in INSTALL a new flexplate. REFER to
this section. Section 303-01 . EXAMINE the starter
Inspect the flexplate for damaged or worn teeth. pinion teeth. If damaged, INSTALL a
Is the noise due to flexplate damage? new starter motor. REFER to Starter
Motor in this section. TEST the system
No
INSTALL a new starter motor. REFER
to Starter Motor in this section. TEST
Component Tests
personal injury.
Always make the Fluke 77-IV Digital Multimeter connections at the component terminal rather than at the
wiring end connector. Making a connection at the wiring end connector could result in false readings because
PINPOINT TEST D: UNUSUAL STARTER NOISE 1628

the meter will not pick up a high resistance between the wiring connector and the component.
Starter Motor - Motor Feed Circuit
1. Make sure the battery is fully charged; carry out the Battery - Condition Test, refer to Section 414-01 .
2. Disconnect the Inertia Fuel Shutoff (IFS) switch.
3. Connect a remote starter switch between the starter solenoid S-terminal and the battery positive (+)
terminal.
4. Connect the Fluke 77-IV Digital Multimeter positive lead to the battery positive (+) post. Connect the
negative lead to the starter solenoid M-terminal.

1 - S-terminal
2 - Remote starter switch
3 10653 Battery
4 - Fluke 77-IV Digital Multimeter
5 - B-terminal
6 - M-terminal
5. Engage the remote starter switch. Read and record the voltage. The voltage reading should be 0.5 volt
or less.
6. If the voltage reading is 0.5 volt or less, go to the starter motor-ground circuit component test.
7. If the voltage reading is greater than 0.5 volt, this is an indication of excessive resistance in the
connections, the positive battery cable or in the starter solenoid. Move the Fluke 77-IV Digital
Multimeter negative lead to the starter solenoid B-terminal and repeat the test. If the voltage reading
at the B-terminal is lower than 0.5 volt, the concern is either in the connections at the starter solenoid
or in the solenoid contacts.
Part Number
Item valign="bottom">Description
1 - S-terminal
2 - Remote starter switch

3 10653 Battery
4 - Fluke 77-IV Digital
Multimeter
5 - B-terminal
6 - M-terminal
8. Remove the cables from solenoid B, S and M-terminals. Clean the cables and connections and
reinstall the cables to the correct terminals. Repeat Steps 3 through 6. If the voltage drop reading is
still greater than 0.5 volt when checked at the M-terminal and less than 0.5 volt when checked at the
B-terminal, the concern is in the solenoid contacts. Install a new starter motor.
9. If the voltage reading taken at the solenoid B-terminal is still greater than 0.5 volt after cleaning the
cables and connections at the solenoid, the concern is either in the positive (+) battery cable
connection or in the positive battery cable itself.
10. Clean the positive (+) battery cable connection. If this does not solve the problem, install a new
positive battery cable.
Starter Motor - Ground Circuit
A slow cranking condition can be caused by resistance in the ground or return portion of the cranking circuit.
Check the voltage drop in the ground circuit as follows:
1. Connect the Fluke 77-IV Digital Multimeter positive lead to the starter motor housing (the connection
must be clean and free of rust or grease). Connect the negative lead to the negative (-) battery
terminal.
2. Engage the remote starter switch and crank the engine. Read and record the voltage reading. The
reading should be 0.2 volt or less.
3. If the voltage droan 0.2 volt, clean the negative cable connections at the battery, the body ground
connections and the starter ground connection. Retest.
4. If the voltage drop is greater than 0.2 volt, install a new cable. If the voltage reading is less than 0.2
volt and the engine still cranks slowly, install a new starter motor.



Starter Motor

1 11N087 Terminal cover
2 N805320 Starter solenoid S-terminal nut
3 14463 Starter solenoid S-terminal eyelet
4 W706414 Starter solenoid B-terminal nut
5 14463 Starter solenoid B-terminal eyelet
6 N805024 Starter motor ground cable nut
7 14463 Starter motor ground cable eyelet
8 W704941 Starter motor mounting stud bolt
9 W704942 Starter motor mounting bolt
10 W704942 Starter motor mounting bolt
11 11000 Starter motor
Removal
personal injury.
100-02 .
Starter Motor 1632

3. Remove the starter terminal cover and remove the nut and the solenoid S-terminal electrical
connection.
4. Remove the nut and the solenoid B-terminal electrical connection.
5. Remove the nut and the starter battery ground cable from the stud.
6. Remove the 2 bolts, the stud bolt and the starter motor.
Installation
1. Position the starter and install the 2 bolts and the stud bolt in 3 stages.
Stage 1: Install the 2 starter bolts and the stud bolt finger-tight.
Stage 2: Tighten the upper bolt to 25 Nm (18 lb-ft).
Stage 3: Tighten the lower bolt and stud bolt to 25 Nm (18 lb-ft).
2. Position the starter battery ground cable onto the stud and install the nut.
3. Connect the solenoid B-terminal electrical connection and install the nut.
4. Connect the solenoid S-terminal electrical connection and install the nut and the starter terminal
cover.
Starter Motor 1633

SECTION 303-07: Engine Ignition - 5.4L (3V) 2011 Expedition, Navigator Workshop Manual
Material

Capacity
Silicone Brake Caliper Grease and ESE-M1C171-A -
Dielectric Compound
XG-3-A
Item Specification
Base ignition timing 10 Before Top Dead Center (BTDC)
Firing order 1-3-7-2-6-5-4-8
Spark plug HJFS-24FP
Spark plug gap 1.05 +/- 0.05 mm (0.039-0.043 in)
Nm lb-in
Ignition coil-on-plug bolts 6 53
Spark plugs 12 106
Starter Motor 1634

Starter Motor 1635

Engine Ignition
The Electronic Ignition (EI) system is a coil-on-plug ignition system. The coil-on-plug ignition system
consists of the following components:
Camshaft Position (CMP) sensor

Ignition coil-on-plugs
Spark plugs
The CMP sensor:
is a variable reluctance sensor.

is triggered by a sensor ring mounted on the crankshaft.
provides base timing and crankshaft speed (rpm) to the PCM.
The separate ignition coils:
change low voltage signals from the PCM to high voltage pulses.
supply the high voltage pulses to the spark plugs.
are connected directly to each spark plug.
The spark plugs:
change high voltage pulses a spark which ignites the fuel and air mixture.
originally equipped on the vehicle have a platinum-enhanced active electrode for long life.
Engine Ignition 1636

Engine Ignition
Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Engine Ignition 1637

Engine Ignition Components - Exploded View
Engine Ignition - RH

1 14A464 RH ignition coil electrical connector (4 required)
2 W711062 RH ignition coil retaining bolt (4 required)
3 12A366 RH ignition coil (4 required)
4 12405 RH spark plug (4 required)
Engine Ignition - LH

1 14A464 LH ignition coil electrical connector (4 required)
2 W711062 LH ignition coil retaining bolt (4 required)
3 12A366 LH ignition coil (4 required)
4 12405 LH spark plug (4 required)
Engine Ignition Components - Exploded View 1638

Engine Ignition - LH 1639

Ignition Coil-On-Plug
Material
Item Specification
Dielectric Compound
XG-3-A
1. Disconnect the ignition coil-on-plug electrical connector.
2. Remove the bolt and the ignition coil-on-plug.

Remove the ignition coil-on-plug, using a twisting motion while pulling up on the ignition
coil-on-plug.
3. NOTE: Verify that the ignition coil-on-plug spring is correctly located inside the ignition
coil-on-plug boot and that there is no damage to the tip of the boot.
To install, rse the removal procedure.
Apply a light coat of dielectric compound to the inside of the ignition coil boots.
Ignition Coil-On-Plug 1640

Spark Plugs
Removal
NOTICE: The spark plug procedure must be followed exactly or damage to the cylinder head and
spark plug will result.
NOTICE: Do not remove the spark plugs when the engine is hot or cold soaked. Spark plug thread or
cylinder head damage can occur. Make sure the engine is warm (hand touch after cooling down) prior
to spark plug removal.
1. Remove the ignition coil-on-plug. For additional information, refer to Ignition Coil-On-Plug in this
section.
2. NOTICE: Only use hand tools when removing or installing the spark plugs or damage can occur
to the cylinder head or spark plug.
NOTE: Use compressed air to remove any foreign material from the spark plug well before removing
the spark plugs.
Remove the spark plug.
3. Inspect the spark plug. For additional information, refer to Section 303-00 .
Installation
1. Adjust the spark plug gap as necessary. For the correct spark plug gap specification, refer to
Specifications in this section.
2. NOTICE: Only use hand tools when removing or installing the spark plugs or damage can occur
to the cylinder head or spark plug.
Install the spark plug.
3. Install the ignition coil-on-plug. For additional information, refer to Ignition Coil-On-Plug in this
section.
Spark Plugs 1641

Spark Plugs 1642

SECTION 303-08: Engine Emission Control 2011 Expedition, Navigator Workshop Manual
Air intake resonator assembly bolt 10 89
PCV fitting bolts 6 53
Spark Plugs 1643

Engine Emission Control
NOTE: Do not permanently remove or render inoperative any part of the vehicle emission control system
including related hardware. Failure to comply may violate applicable state and federal law.
NOTE: The vehicle emission vacuum routing diagrams are contained in the Description and Operation
subsection of the Evaporative Emissions section. Refer to Section 303-13 .
The gasoline engine emission control system consists of the PCV system.
PCV System
The PCV system:
uses intake manifold vacuum to ventilate blow-by gases from the crankcase.
returns the gases to the intake manifold for combustion.
The PCV valve:
varies the amount of blow-by gases returned to the intake manifold based on available engine
vacuum.
is integral to the LH valve cover.
Engine Emission Control 1644

Engine Emission Control
Engine Emission Control 1645

Positive Crankcase Ventilation (PCV) System Components
Part
1 - Throttle Body (TB) adapter-to-air intake resonator
assembly clamp
3 9F763 Air intake resonator assembly
4 6K817 PCV tube
6 9F624 PCV fitting
Removal
to Section 310-00 .
3. Remove the 2 bolts and the PCV fitting.
Installation
1. Install the PCV fitting and the 2 bolts.

Section 310-00 .
Positive Crankcase Ventilation (PCV) System Components 1646

&nbsp

SECTION 303-12: Intake Air Distribution and Filtering 2011 Expedition, Navigator Workshop Manual
Air Cleaner (ACL) outlet pipe clamp 4 35
Engine appearance cover bolts 5 44
Mass Air Flow (MAF) sensor bolts 3 27


SECTION 303-12: Intake Air Distribution and Filtering
Manual
Intake Air Distribution and Filtering
The air intake system consists of the following:
Air Cleaner (ACL) housing

ACL element
ACL outlet tube
Mass Air Flow (MAF) sensor
The air intake system:
cleans intake air with a replaceable ACL element.

measures airflow with a MAF sensor. For additional information, refer to Section 303-14 .
Intake Air Distribution and Filtering 1649


SECTION 303-12: Intake Air Distribution and Filtering
Manual
Intake Air Distribution and Filtering
Refer to Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Intake Air Distribution and Filtering 1650

Intake Air System Components - Exploded View
Part
1 W713295 Engine appearance cover bolt (2 required) (Navigator
only)
2 6A949 Engine appearance cover (Navigator only)
3 9F805 Navigator Air Cleaner (ACL) outlet pipe and resonator
assembly
4 9F805 Expedition ACL outlet pipe and resonator assembly
5 14A464 Mass Air Flow (MAF) electrical connector
6 W709287 MAF sensor bolt (2 required)
7 12B579 MAF sensor
8 9661 ACL housing cover
9 9A600 ACL element
Intake Air System Components - Exploded View 1651

Intake Air System Components - Exploded View 1652

Air Cleaner Element
1. Disconnect the Air Cleaner (ACL) outlet pipe from the ACL cover.
To install, tighten the clamps to 4 Nm (35 lb-in).
2. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
3. Release the retaining clips and position the ACL cover aside.
4. Remove the ACL element.
5. NOTE: The ACL element must be fully seated into the ACL housing. Failure to do so will result in
unusual engine noise.
Air Cleaner Element 1653

Air Cleaner
1. The Air Cleaner (ACL) housing is an integral part of the degas bottle and cannot be serviced
separately. For additional information, refer to Section 303-03 .
Air Cleaner 1654

Air Cleaner Outlet Pipe
Removal
Navigator
1. Remove the 2 bolts and the engine appearance cover.
All vehicles
2. Loosen the 2 Air Cleaner (ACL) outlet pipe clamps.
3. Remove the ACL outlet pipe.
Installation
Navigator
1. NOTE: The ACL outlet pipe should be securely sealed, with the ends flush with the flanges on both
the ACL and the Throttle Body (TB) to prevent unusual engine noise.
Position the ACL outlet pipe with the alignment indicator positioned as shown and tighten the 2
clamps.
Expedition
2. NOTE: The ACL outlet pipe should be securely sealed, with the ends flush with the flanges on both
the ACL and the TB to prevent unusual engine noise.
Position the ACL outlet pipe and tighten the 2 clamps.
Navigator
3. Position the engine appearance cover and install the 2 bolts.

Air Cleaner Outlet Pipe 1655


SECTION 303-13: Evaporative Emissions 2011 Expedition, Navigator Workshop Manual

Evaporative Emission (EVAP) canister assembly bracket and exhaust Y-pipe dual catalytic 20 177
converter heat shield-to-transmission crossmember bolt
EVAP canister assembly bracket-to- EVAP canister bolts 6 53
EVAP canister assembly bracket-to-frame rail bolts 20 177


Evaporative Emissions
The Evaporative Emission (EVAP) system consists of the following:
EVAP canister assembly (located in front of the fuel tank)

EVAP canister purge valve and hose assembly (located on the back side of the intake manifold)
EVAP canister vent solenoid and dust separator assembly (attached to the EVAP canister)
EVAP canister vent solenoid and dust separator assembly quick connect coupling fitting (attached to
the EVAP canister vent solenoid and dust separator assembly)
Fuel Tank Pressure (FTP) sensor and vapor tube assembly (located on top of the fuel tank)
Vapor tubes
The EVAP system:
prevents hydrocarbon emissions from reaching the atmosphere.

stores fuel vapors in the EVAP canister that are generated during vehicle operation or hot soak, until
they can be consumed by the engine during normal engine operation.
routes the stored fuel vapors to the engine during engine operation.
is controlled by the PCM, which uses various sensor inputs to calculate the desired amount of purge
flow. The PCM regulates the purge flow, induced by the application of intake manifold vacuum, by
varying the duty cycle applied to the EVAP canister purge valve.
The fuel vapors are routed:
from the fuel tank through the fuel vapor/grade vent valves.
to the EVAP canister through a vapor line.
to the engine when the EVAP canister purge valve is opened by the PCM.
The FTP sensor:
measures the pressure levels in the fuel tank continuously.

serves as input to the PCM.
The EVAP canister:
contains activated carbon.

stores fuel vapors.
The Easy Fuel TM capless fuel tank filler assembly:
relieves system vacuum below 3.8 kPa (15.26 in H 2 O).
The canister vent solenoid:
is controlled by the PCM.

is normally open.
seals the EVAP system for the OBD II leak and pressure tests.
is mounted to the EVAP canister.
is repaired through removal/replacement of the canister vent solenoid and dust separator assembly.
The canister vent solenoid must not be serviced separately from the canister vent solenoid and dust
separator assembly.
Evaporative Emissions 1658

The EVAP canister purge valve:
is normally closed.
regulates the purging of the EVAP canister.
is controlled by the PCM.
The Engine On EVAP leak-check monitor:
uses intake manifold vacuum to reach a target vacuum on the EVAP system. The FTP sensor is used
by the Engine On EVAP leak-check monitor to determine if the target vacuum necessary to carry out
the leak-check on the EVAP system has been reached. Once target vacuum on the EVAP system is
achieved, the change in EVAP system vacuum over a calibrated period of time determines if a leak
exists.
The Engine Off Natural Vacuum (EONV) EVAP leak-check monitor is executed:
once the Engine On EVAP leak-check monitor is completed and the key is turned off. The EONV
EVAP leak-check monitor determines if a leak is present when the naturally occurring change in the
fuel tank pressure or vacuum does not exceed a calibrated limit during a calibrated amount of time. A
separate, low-power consuming microprocessor in the PCM manages the EONV leak-check.
Vehicle Emission Vacuum Routing
Part
1 6582 RH valve cover
2 9A589 Air Cleaner (ACL) outlet pipe-to-Throttle Body (TB)
adapter
3 - Four-Wheel Drive (4WD) vacuum solenoid assembly
4 6A505 LH valve cover
5 9F624 PCV fitting
6 - Brake booster
7 9Y451 Intake manifold
8 9C915 Evaporative Emission (EVAP) canister purge valve
9 9D653 EVAP canister assembly
10 9F675 EVAP canister vent solenoid and dust separator
assembly
11 9K007 Fuel tank
12 - Fuel vent valve



Evaporative Emissions


Evaporative Emission System Leak Test
Special Tool(s)
VACUTEC Smoke Machine Fuel EVAP

Emissions System Tester
Phase 1 - Leak Verification
1. Run the EVAP Test with the scan tool.
2. NOTE: Some small leaks may not be detected using the EVAP Test. If the system has passed the test
but a leak is still suspected, then proceed to Phase 2.
If the Evaporative Emission (EVAP) system failed the EVAP Test, then proceed to Phase 2.
Phase 2 - System Leak Check
1. Disconnect the fuel vapor tube-to- EVAP canister purge valve quick connect coupling. For additional
2. Connect the VACUTEC Smoke Machine Fuel EVAP Emissions System Tester to the fuel vapor tube
quick connect coupling. For additional information, refer to the manufacturer's instructions.
3. NOTE: The battery ground cable was previously disconnected in the fuel vapor tube quick connect
coupling procedure.p>Connect the battery ground cable. For additional information, refer to Section
414-01 .
4. Close the canister vent solenoid with the scan tool.
5. NOTE: The supplemental refueling adapter is located in the jack storage compartment.
Install the supplemental refueling adapter into the Easy Fuel TM (capless) fuel tank filler pipe
assembly.
6. NOTE: If smoke does not exit the fuel tank filler pipe neck area after the system is pressurized, open
the canister vent solenoid with the scan tool to allow the air to purge. Once smoke is seen at the
canister vent solenoid, close the canister vent solenoid with the scan tool.
Introduce smoke from the VACUTEC Smoke Machine Fuel EVAP Emissions System Tester into the
EVAP system and verify that smoke is exiting the fuel tank filler pipe neck area. For additional
information, refer to the manufacturer's instructions.
7. Remove the supplemental refueling adapter once smoke is observed exiting the fuel tank filler pipe
neck area.
Evaporative Emission System Leak Test 1662

8. Continue to enter smoke into the system for 60 seconds to obtain pressure.
9. Press and release the remote start button in intervals of 15 seconds ON and 15 seconds OFF while
checking for exiting smoke.
10. Use the halogen light provided with the VACUTEC Smoke Machine Fuel EVAP Emissions System
Tester to follow the EVAP system path and look for smoke exiting at the source of the leak(s).
11. Repair any leaks as necessary.
12. Repeat the EVAP Leak Test until the system passes.
Evaporative Emission System Leak Test 1663


Evaporative Emission (EVAP) System Components - Exploded View
Evaporative Emission (EVAP) Canister Assembly
NOTE: 106L (28 gal) fuel tank vapor tubes shown, 127L (33.5 gal) similar.
Part
1 - Evaporative Emission (EVAP) canister vent solenoid
electrical connector (part of 14405)
2 - Fuel Tank Pressure (FTP) sensor and vapor tube
assembly-to- EVAP canister quick connect coupling (part
of 9C015)
3 - EVAP canister purge valve vapor tube-to- EVAP canister
quick connect coupling (part of 9D676)
4 - Fresh air tube-to-canister vent solenoid and dust separator
assembly quick connect coupling (part of 9S327)
5 W506423 EVAP
6 W707959 EVAP canister assembly bracket and exhaust Y-pipe dual
catalytic converter heat shield-to-transmission
crossmember bolt
7 9E857 EVAP canister assembly
8 W506423 EVAP canister assembly bracket-to-frame rail bolt
Evaporative Emission (EVAP) System Components - Exploded View 1664

EVAP Canister, Vent Solenoid and Dust Separator and Brackets
Part
1 9D857 Evaporative Emission (EVAP) canister vent solenoid
electrical jumper
2 9E629 Canister vent solenoid and dust separator assembly
quick connect coupling fitting
3 9B328 Canister vent solenoid and dust separator assembly
4 9D653 EVAP canister
5 9D694 EVAP canister heat shield (service only)
6 9R543 EVAP canister assembly bracket-to- EVAP canister bolt
(3 required)
7 9D665 EVAP canister assembly bracket and heat shield
8 9D665 EVAP canister assembly bracket
9 W500213 EVAP canister assembly bracket-to- EVAP canister bolt
(2 required)
EVAP Canister, Vent Solenoid and Dust Separator and Brackets 1665
EVAP Canister, Vent Solenoid and Dust Separator and Brackets 1666

Evaporative Emission Canister
NOTE: The Evaporative Emission (EVAP) canister vent solenoid and dust separator are an assembly.
100-02 .
3. Disconnect the EVAP canister vent solenoid electrical jumper from the wiring harness.
4. Disconnect the Fuel Tank Pressure (FTP) sensor and vapor tube assembly-to- EVAP canister quick
connect coupling. For additional information, refer to Section 310-00 .
5. Disconnect the EVAP canister purge valve vapor tube-to- EVAP canister quick connect coupling. For
6. Disconnect the fresh air tube-to-canister vent solenoid and dust separator assembly quick connect
coupling. For additional information, refer to Section 310-00 .
7. Remove the EVAP canister assembly bracket-to-frame rail bolt in the rear.
8. Remove the EVAP canister assembly bracket-to-frame rail bolt in the front.
9. Remove the EVAP canister assembly bracket and exhaust Y-pipe dual catalytic converter heat
shield-to-transmission crossmember bolt and remove the EVAP canister assembly from the vehicle.
10. Disconnect the EVAP canister vent solenoid electrical connector.
11. Remove the 5 EVAP canister-to- EVAP canister assembly bracket bolts.
12. Remove the EVAP canister assembly from the EVAP canister assembly brackets.
13. Remove the canister vent solenoid and dust separator assembly from the EVAP canister.
14. NOTE: Inspect the EVAP canister heat shield and if damaged, install a new EVAP canister heat
shield.
Evaporative Emission Canister 1667

Carry out the Evaporative Emission System Leak Test. For additional information, refer to
Evaporative Emission System Leak Test in this section.
Evaporative Emission Canister 1668


Evaporative Emission Canister Vent Solenoid
NOTE: The Evaporative Emission (EVAP) canister vent solenoid and dust separator are an assembly.
100-02 .
3. Disconnect the EVAP canister vent solenoid electrical jumper from the wiring harness.
4. Disconnect the Fuel Tank Pressure (FTP) sensor and vapor tube assembly-to- EVAP canister quick
5. Disconnect the EVAP canister purge valve vapor tube-to- EVAP canister quick connect coupling. For
6. Disconnect the fresh air tube-to-canister vent solenoid and dust separator assembly quick connect
coupling. For additional information, refer to Section 310-00 .
7. Remove the EVAP canister assembly bracket-to-frame rail bolt in the rear.
8. Remove the EVAP canister assembly bracket-to-frame rail bolt in the front.
9. Remove the EVAP canister assembly bracket and exhaust Y-pipe dual catalytic converter heat
shield-to-transmission crossmember bolt and remove the EVAP canister assembly from the vehicle.
10. Disconnect the EVAP canister vent solenoid electrical connector.
11. Remove the 2 EVAP canister-to- EVAP canister assembly bracket bolts in the front of the canister.
12. Remove the canister vent solenoid and dust separator assembly from the EVAP canister.

Evaporative Emission Canister Vent Solenoid 1669

Evaporative Emission Canister Vent Solenoid 1670


Dust Separator
1. NOTE: The Evaporative Emission (EVAP) canister vent solenoid and dust separator are an assembly.
This assembly is removed with the EVAP canister vent solenoid.
For additional information, refer to Evaporative Emission Canister Vent Solenoid in this section.
Dust Separator 1671


Evaporative Emission Canister Purge Valve

1 - Evaporative Emission (EVAP) canister-to-
EVAP canister purge valve vapor tube quick
connect coupling (part of 9J337)
2 - EVAP canister purge valve electrical connector
(part of 12B637)
3 9E360 EVAP canister purge valve and hose assembly
ignited. Failure to follow these instructions may result in serioersonal injury.
2. Disconnect the Evaporative Emission (EVAP) canister purge valve and hose electrical connector.
3. Disconnect EVAP canister purge valve hose-to-intake manifold quick connect coupling. For
4. Disconnect the EVAP canister-to- EVAP canister purge valve and hose assembly vapor tube quick
5. Slide the EVAP canister purge valve and hose assembly off the bracket.

Evaporative Emission Canister Purge Valve 1672

Evaporative Emission Canister Purge Valve 1673


Fuel Tank Pressure Sensor
106L (28 Gal) Fuel Tank

1 - Fuel Tank Pressure (FTP) sensor and vapor
tube assembly-to-fuel vapor/grade vent valve
quick connect coupling (part of 9C015)
2 - FTP sensor (part of 9C015)
3 - FTP sensor and vapor tube assembly-to-fuel
pump module quick connect coupling (part of
9C015)
4 - FTP sensor and vapor tube assembly (part of
9C015)
5 - FTP sensor and vapor tube assembly-to-fuel
vapor/grade vent valve quick connect
coupling (part of 9C015)
6 9A032 Heat shield
7 - Fuel supply tube-to-heat shield pushpin
retainer
8 9002 Fuel tank
127L (33.5 Gal) Fuel Tank
Fuel Tank Pressure Sensor 1674

Part
2 - FTP sensor (part of 9C015)
3 9C015 FTP sensor and vapor tube assembly
4 - FTP sensor and vapor tube assembly-to-fuel vapor/grade
vent valve quick connect coupling (part of 9C015)
5 388890 Heat shield retainer
6 - FTP sensor and vapor tube assembly-to-fuel pump
module quick connect coupling (part of 9C015)
7 388890 Heat shield retainer
8 9K014 Heat shield
9 9002 Fuel tank
All fuel tanks
1. Remove the fuel tank. For additional information, refer to Section 310-01 .
2. Disconnect the fuel supply tube-to-heat shield pushpin retainer.
127L (33.5 gal) fuel tank
3. Remove the fuel tank heat shield retainer(s).
All fuel tanks
4. Remove the fuel tank heat shield.
5. Disconnect the Fuel Tank Pressure (FTP) sensor and vapor tube assembly-to-fuel vapor/grade vent
valves quick connect couplings. For additional information, refer to Section 310-00 .
6. Disconnect the FTP sensor and vapor tube assembly-to-fuel pump module quick connect coupling.
7. Remove the FTP sensor and vapor tube assembly from the fuel tank.

127L (33.5 Gal) Fuel Tank 1675


SECTION 303-14: Electronic Engine Controls 2011 Expedition, Navigator Workshop Manual
Material

Capacity
High Temperature Nickel - -
Anti-Seize Lubricant
XL-2
XO-5W20-QSP (US);
Penetrating and Lock Lubricant - -
(US); Penetrating Fluid (Canada)

A/C compressor bolts 25 18 -
Camshaft Position (CMP) sensor bolt 10 - 89
Catalyst Monitor Sensor (CMS) 46 34 -
Crankshaft Position (CKP) sensor bolt 10 - 89
Cylinder Head Temperature (CHT) sensor 10 - 89
Heated Oxygen Sensor (HO2S) 46 34 -
Knock Sensor (KS) bolt align="center">20 - 177
Mass Air Flow (MAF) sensor bolts 3 - 27
PCM stud bolts 9 - 80
Throttle Position (TP) sensor screws 3 - 27
Variable Camshaft Timing (VCT) oil control solenoid bolt 5 - 44


Electronic Engine Controls
The electronic engine controls consist of the following:
RH and LH Camshaft Position (CMP) sensor

RH and LH Catalyst Monitor Sensor (CMS)
Crankshaft Position (CKP) sensor
Cylinder Head Temperature (CHT) sensor
RH and LH Heated Oxygen Sensor (HO2S)
RH and LH Knock Sensor (KS)
Mass Air Flow (MAF) sensor
PCM
Throttle Position (TP) sensor
RH and LH Variable Camshaft Timing (VCT) oil control solenoids
The PCM needs the following inputs to calibrate the engine correctly:
Air temperature
Amount of engine detonation
Camshaft position
Crankshaft position
Cylinder head temperature
Engine coolant temperature
Engine rpm
Exhaust oxygen content
Mass airflow
Throttle position
Camshaft Position (CMP) Sensor
The CMP sensor:
sends the PCM a signal indicating camshaft position used for fuel synchronization and coil firing.
For removal and installation, refer to Camshaft Position (CMP) Sensor in this section.
Crankshaft Position (CKP) Sensor
The CKP sensor:
sends the PCM a signal indicating crankshaft position.

is essential for calculating spark and fuel timing.
For removal and installation, refer to Crankshaft Position (CKP) Sensor in this section.
Cylinder Head Temperature (CHT) Sensor
The CHT sensor:
Electronic Engine Controls 1679

is mounted into the front of the left cylinder head and is not connected to any coolant passages.
sends a signal to the PCM indicating the cylinder head temperature.
For removal and installation, refer to Cylinder Head Temperature (CHT) Sensor in this section.
Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS)
The RH and LH HO2S and RH and LH CMS :
create a voltage signal dependent on exhaust oxygen content.

provide feedback information to the PCM used to calculate fuel delivery.
For removal and installation, refer to Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded
View and Heated Oxygen Sensor (HO2S) or Catalyst Monitor Sensor in this section.
Knock Sensor (KS)
The RH and LH KS :
are located in the intake valley of the cylinder block.

sends a signal to the PCM indicating engine detonation.
For removal and installation, refer to Knock Sensor (KS) in this section.
Mass Air Flow (MAF) Sensor
The MAF sensor:
sends the PCM a signal indicating mass airflow rate of air entering the engine.
incorporates the Intake Air Temperature (IAT) sensor.
For removal and installation, refer to Mass Air Flow (MAF) Sensor in this section.
PCM
The PCM carries out the following functions:
accepts input from various engine sensors to compute the fuel flow rate necessary to maintain a
prescribed air/fuel ratio throughout the entire engine operational range.
outputs a command to the fuel injectors to meter the appropriate quantity of fuel.
For removal and installation, refer to Powertrain Control Module (PCM) in this section.
Throttle Position (TP) Sensor
The TP sensor:
sends the PCM a signal indicating the throttle plate angle.

For removal and installation, refer to Throttle Position (TP) Sensor in this section.
Variable Camshaft Timing (VCT) Oil Control Solenoid
The VCT oil control solenoid:
is an electrically controlled hydraulic valve that directs engine oil to the variable camshaft. Once the
PCM transmits a signal, the solenoid moves a valve spool, directing oil into the camshaft phaser
cavity. This action changes valve timing by either inducing an advance or retard condition. The
camshaft is thereby repositioned in relation to crankshaft timing and allows for optimum engine
performance and emissions.
For removal and installation, refer to Variable Camshaft Timing (VCT) Oil Control Solenoid in this section.

Electronic Engine Controls
DTC Charts
PCM DTC Chart
DTC Description Action to Take

P0125 Insufficient Coolant Temp For Closed Loop Fuel REFER to Section 303-03 .
Control
P0128 Coolant Thermostat (Coolant Temp Below REFER to Section 303-03 .
Thermostat Regulating Temperature)
P0217 Engine Coolant Overtemperature Condition REFER to Section 303-03 .
P0512 Starter Request Circuit REFER to Section 303-06 .
P0532 A/C Refrigerant Pressure Sensor A Circuit Low REFER to Section 412-00 .
P0533 A/C Refrigerant Pressure Sensor A Circuit High REFER to Section 412-00 .
P0562 System Voltage Low REFER to Section 414-00 .
P0563 System Voltage High REFER to Section 414-00 .
P0579 Cruise Control Multi-Function Input A Circuit REFER to Section 419-03 .
Range/Performance
P0581 Cruise Control Multi-Function Input A Circuit REFER to Section 419-03 .
High
P0602 Powertrain Control Module Programming Error REFER to Section 418-01 .
P0605 Internal Control Module Read Only Memory REFER to Section 418-01 .
(ROM) Error
P0620 Generator Control Circuit REFER to Section 414-00 .
P0625 Generator Field Terminal Circuit Low REFER to Section 414-00 .
P0626 Generator Field Terminal Circuit High REFER to Section 414-00 .
P0645 A/C Clutch Relay Control Circuit REFER to Section 412-00 .
P065B Generator Control Circuit Range/Performance REFER to Section 414-00 .
P1260 Theft Detected, Vehicle Immobilized REFER to Section 419-01B .
P1285 Cylinder Head Overtemperature Condition REFER to Section 303-03 .
P1299 Cylinder Head Overtemperature Protection Active REFER to Section 303-03 .
P1464 A/C Demand Out Of Self Test Range REFER to Section 412-00 .
P1572 Brake Pedal Switch Circuit REFER to Section 419-03 .
P1602 Immobilizer/ ECM Communication Error a REFER to Section 419-01B .
P1622 Immobilizer ID Does Not Match REFER to Section 419-01B .
P1639 Vehicle ID Block Corrupted, Not Programmed REFER to Section 418-01 .
P1703 Brake Switch Out Of Self Test Range REFER to Section 419-03 .
U0300 Internal Control Module Software Incompatibility REFER to Section 418-01 .
U2051 One or More Calibration Files Missing / Corrupt REFER to Section 418-01 .
All Other - REFER to Powertrain Control/Emissions
DTCs Diagnosis (PC/ED) manual.

a ECM: Engine Control Module

Variable Camshaft Timing (VCT) Oil Control Solenoid
Part
1 6C260 Variable Camshaft Timing (VCT) oil control solenoid
bolt
1. Remove the valve cover. For additional information, refer to Section 303-01 .
2. Remove the bolt and the Variable Camshaft Timing (VCT) oil control solenoid.
Variable Camshaft Timing (VCT) Oil Control Solenoid 1684

Variable Camshaft Timing (VCT) Oil Control Solenoid 1685

Camshaft Position (CMP) Sensor
Material
Item Specification
XO-5W20-QSP (US);
Part
1 - RH Camshaft Position (CMP) sensor electrical
connector (part of 12B637)
2 N806155-S RH CMP sensor bolt
3 6B288 RH CMP sensor
4 6758 RH CMP sensor O-ring seal
5 - LH CMP sensor electrical connector (part of 12B637)
6 N806155-S LH CMP sensor bolt
7 6B288 LH CMP sensor
8 6758 LH CMP sensor O-ring seal
LH Camshaft Position (CMP) sensor
All CMP sensors
2. Disconnect the Camshaft Position (CMP) sensor electrical connector.
Camshaft Position (CMP) Sensor 1686

3. Remove the bolt and the CMP sensor.

Camshaft Position (CMP) Sensor 1687

Crankshaft Position (CKP) Sensor
Special Tool(s)

Material
Item Specification
XO-5W20-QSP (US);
Part
1 N806184 A/C compressor bolt (3 required)
2 19703 A/C compressor
3 - Crankshaft Position (CKP) sensor electrical connector
(part of 12B637)
4 N806155 CKP sensor bolt
5 6C315 CKP sensor
100-02 .
2. Rotate the accessory drive belt tensioner clockwise and detach the accessory drive belt from the A/C
compressor pulley.
Crankshaft Position (CKP) Sensor 1688

3. Disconnect the A/C compressor electrical connector.
5. Remove the 3 bolts and position the A/C compressor aside.

6. Remove the bolt and the CKP sensor.

8. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the
on-screen instructions.
Crankshaft Position (CKP) Sensor 1689

Powertrain Control Module (PCM)
Special Tool(s)


1 14A464 PCM electrical connector (3 required)
2 W711897 PCM stud (2 required)
3 12A630 PCM
4 12A696 PCM gasket
1. NOTE: Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for correct Vehicle
Communication Module (VCM) hook-up procedure.
If servicing the PCM, connect the scan tool to the vehicle. Allow the scan tool to identify the vehicle
and obtain configuration data.
All programmable module information will automatically be retrieved by the VCM .
3. Disconnect the 3 PCM electrical connectors.
4. Remove the 2 stud bolts and the PCM.

5. NOTE: If the Instrument Cluster (IC) or the PCM is being replaced (or both), the parameters must be
reset in both modules or the vehicle will experience a Passive Anti-Theft System (PATS) no-start.
This will occur even if the vehicle is not equipped with PATS . For additional information, refer to
Powertrain Control Module (PCM) 1690

Passive Anti-Theft System (PATS) Parameter Reset in Section 419-01B .
NOTE: If the Programmable Module Installation (PMI) procedure was not successful in downloading
the data from the vehicles original PCM, then the oil life data of the vehicle is lost. If this occurs, and
the oil life cannot be determined through service history or customer interview, it is recommended the
vehicle engine oil and filter be changed and the oil change minder reset.
6. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the
on-screen instructions.
Powertrain Control Module (PCM) 1691

Throttle Position (TP) Sensor
Removal
1. Remove the Throttle Body (TB). For additional information, refer to Section 303-04 .
2. NOTICE: Do not put direct heat on the Throttle Position (TP) sensor or any other plastic parts
because heat damage may occur. Damage may also occur if Electronic Throttle Body (ETB)
temperature exceeds 120C (248F).
NOTE: Do not use power tools.
Remove the Throttle Position (TP) sensor.
1. Using a heat gun, apply heat to the top of the Electronic Throttle Body (ETB) until the top TP
sensor bolt ear reaches approximately 55C (130F), this should take no more than 3 minutes
using an 1,100-watt heat gun. The heat gun should be about 25.4 mm (1 in) away from the
ETB .
2. Monitor the temperature of the top TP sensor bolt ear on the ETB with a digital temperature
laser or infrared thermometer, while heating the ETB .
i>Using hand tools, quickly remove the bolt farthest from the heat source first and discard.
4. Using hand tools, remove the remaining bolt and discard.
5. Remove and discard the TP sensor.
Installation
1. NOTE: When installing the new TP sensor, make sure that the radial locator tab on the TP sensor is
aligned with the radial locator hole on the ETB .
NOTE: Do not use power tools.
Install the new TP sensor.
Using hand tools, install the 2 new bolts.

Throttle Position (TP) Sensor 1692

2. Install the TB . For additional information, refer to Section 303-04 .
Throttle Position (TP) Sensor 1693

Mass Air Flow (MAF) Sensor
Part
1 - Mass Air Flow (MAF) sensor electrical connector (part
of 12B637)
2 W505562 MAF sensor bolt (2 required)
3 12B579 MAF sensor
1. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Remove the 2 bolts and the MAF sensor.

Mass Air Flow (MAF) Sensor 1694

Mass Air Flow (MAF) Sensor 1695

Knock Sensor (KS)
Part
1 - RH Knock Sensor (KS) electrical connector (part of
12B637)
2 W500225 RH KS bolt
3 12A699 RH KS
4 14A464 LH KS electrical connector
5 W500225 LH KS bolt
6 12A699 LH KS
1. Remove the intake manifold. For additional information, refer to Section 303-01 .
2. Disconnect the Knock Sensor (KS) electrical connectors.
3. Remove the 2 bolts and the 2 KS .

4. To install, reverse e removal procedure.
Knock Sensor (KS) 1696

Knock Sensor (KS) 1697

Cylinder Head Temperature (CHT) Sensor
Material
Item Specification
High Temperature Nickel Anti-Seize -
Lubricant
XL-2

1 - Cylinder Head Temperature (CHT) sensor
electrical connector (part of 12B637)
2 6G004 CHT sensor
1. Remove the intake manifold. For additional information, refer to Section 303-01 .
2. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
3. Remove the CHT sensor and discard.

Coat the new CHT sensor threads with high temperature nickel anti-seize lubricant prior to
instalon.
Cylinder Head Temperature (CHT) Sensor 1698

Cylinder Head Temperature (CHT) Sensor 1699

Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View
Part
1 - Heated Oxygen Sensor (HO2S) electrical connectors
(part of 12B637) (2 required)
2 9F472 HO2S (2 required)
3 - Catalyst Monitor Sensor (CMS) electrical connectors
(part of 12B637) (2 required)
4 9G444 CMS (2 required)
Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View 1700
Heated Oxygen Sensor (HO2S)
Special Tool(s)
Socket, Exhaust Gas Oxygen Sensor

303-476 (T94P-9472-A)
Material
Item Specification
Lubricant
XL-2
Removal
100-02 .
2. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector.
3. Using the Exhaust Gas Oxygen Sensor Socket, remove the HO2S .
Apply penetrating lubricant to the HO2S to assist in removal.
Installation
1. Install the HO2S .

Apply a light coat of high temperature nickel anti-seize lubricant to the HO2S threads prior to
installation.
Calculate the correct torque wrench setting for the following torque. Refer to the Torque
Wrench Adapter Formulas in the Appendix.
Using the Exhaust Gas Oxygen Sensor Socket, tighten to 46 Nm (34 lb-ft).
Heated Oxygen Sensor (HO2S) 1701

2. Connect the HO2S electrical connector.
Heated Oxygen Sensor (HO2S) 1702

Catalyst Monitor Sensor
Special Tool(s)
Socket, Exhaust Gas Oxygen Sensor

303-476 (T94P-9472-A)
Material
Item Specification
Lubricant
XL-2
Removal
100-02 .
2. Disconnect the Catalyst Monitor Sensor (CMS) electrical connector.
3. Using the Exhaust Gas Oxygen Sensor Socket, remove the CMS .
Apply penetrating lubricant to the CMS to assist in removal.
Installation
1. Install the CMS .

Apply a light coat of high temperature nickel anti-seize lubricant to the CMS threads prior to
installation.
Calculate the correct torque wrench setting for the following torque. Refer to the Torque
Wrench Adapter Formulas in the Appendix.
Using the Exhaust Gas Oxygen Sensor Socket, tighten to 46 Nm (34 lb-ft).
Catalyst Monitor Sensor 1703

2. Connect the CMS electrical connector.

SECTION 204-00: Suspension System - General 2011 Expedition, Navigator Workshop

Information Manual
Alignment Specifications Vehicles With Rear Coil Spring Suspension
Item LH RH Total/ Split

Expedition
Camber (Front) -0.3 -0.3 0 0.75
0.75 0.75
Caster (Front) 3.9 1.0 4.5 1.0 -0.6 0.75
Total toe (Front) @ curb ride - - 0.14 0.20 Camber -0.5 -0.5 -
height (Rear) 0.75 0.75
Total toe (Rear) @ trim ride 0.10 0.10 0.20 0.20
height 0.20 0.20
Expedition EL
Camber (Front) -0.3 -0.3 0 0.75
0.75 0.75
Caster (Front) 4.0 1.0 4.6 1.0 -0.6 0.75
Total toe (Front) @ curb ride - - 0.14 0.20
height
Camber (Rear) -0.5 -0.5 -
0.75 0.75
height 0.20 0.20
Navigator
Camber (Front) -0.3 -0.3 0 0.75
0.75 0.75
Caster (Front) 3.9 1.0 -0.6
0.75
Total toe (Front) @ trim ride - - 0.14 0.20
height
0.75 0.75
height 0.20 0.20
Navigator L
Camber (Front) -0.3 -0.3 0 0.75
0.75 0.75
Caster (Front) 4.1 1.0 4.7 0.75 -0.6 0.75
Total toe (Front) @ curb ride - - 0.14 0.20
height
0.75 0.75
0.20 0.20

Total toe (Rear) @ trim ride 0.10 0.10

height 0.20 0.20
Alignment Specifications Vehicles With Rear Air Suspension
LH RH Total/ Split
Rear Wheel Drive (RWD) Expedition
Camber (Front) -0.3 0.75 -0.3 0.75 0 0.75
Caster (Front) 4.1 1.0 4.7 1.0 -0.6 0.75
height
Camber (Rear) -0.5 0.75 -0.5 0.75 -
Total toe (Rear) @ trim ride 0.10 0.20 0.10 0.20 0.20 0.20
height
RWD Navigator
Camber (Front) -0.3 0.75 -0.3 0.75 0 0.75
Caster (Front) 4.1 1.0 4.7 1.0 -0.6 0.75
- - 0.14 0.20
Camber (Rear) -0.5 0.75 -0.5 0.75 -
height
RWD Expedition EL/Navigator L
Camber (Front) -0.3 0.75 -0.3 0.75 0 0.75
Caster (Front) 4.2 1.0 4.8 1.0 -0.6 0.75
height
Camber (Rear) -0.5 0.75 -0.5 0.75 -
height
Four-Wheel Drive (4WD) Expedition/NFront) -0.3 0.75 -0.3 0.75 0
0.75
Caster (Front) 4.0 1.0 4.6 1.0 -0.6 0.75
height
Camber (Rear) -0.5 0.75 -0.5 0.75 -
height
4WD Expedition EL/Navigator L
Camber (Front) -0.3 0.75 -0.3 0.75 0 0.75
Caster (Front) 4.1 1.0 4.7 1.0 -0.6 0.75
height
Camber (Rear) -0.5 0.75 -
height

Item Specification
Ball Joint Deflection
Lower 0-0.8 mm (0-0.032 in)
Upper 0-0.2 mm (0-0.008 in)
Front Ride Height (Full Fluids, Including Fuel)
Rear Wheel Drive (RWD) Expedition with rear coil 105 mm (4.133 in)
spring suspension without Roll Stability Control
(RSC) 12 mm (0.472 in)
RWD Expedition with rear coil spring suspension 107 mm (4.212 in)
with RSC
12 mm (0.472 in)
Four-Wheel Drive (4WD) Expedition with rear coil 108 mm (4.251 in) 106 mm
spring suspension with RSC (4.173
12 mm (0.472 in) 4WD Expedition with in)
rear coil spring suspension without RSC
12 mm
(0.472
in)
RWD Expedition EL with rear coil spring suspension 109 mm (4.291 in)
without RSC
8 mm (0.314 in)
4WD Expedition EL with rear coil spring suspension 110 mm (4.330 in)
12 mm (0.472 in) (w/o RSC )

with RSC
12 mm (0.472 in)
RWD Navigator with rear coil spring suspension 98 mm (3.858 in)
12 mm (0.472 in) (w/o RSC )

4WD Navigator with rear coil spring suspension 101 mm (3.976 in)
12 mm (0.472 in) (w/o RSC )

RWD Navigator L with rear coil spring suspension 107 mm (4.212 in)
12 mm (0.472 in) (w/o RSC )

4WD Navigator L with rear coil spring suspension 109 mm (4.291 in)
12 mm (0.472 in) (w/o RSC )

Expedition with rear air suspension 108 mm (4.251 in)
12 mm (0.472 in)
Expedition EL with rear air suspension 110 mm (4.330 in)
12 mm (0.472 in)
RWD Navigator L with rear air suspension 98 mm (3.858 in)
12 mm (0.472 in)

4WD Navigator L with rear air suspension 101 mm (3.976 in)
12 mm (0.472 in)
Rear Ride Height (Full Fluids, Including Fuel)
RWD Expedition with rear coil spring suspension 101 mm (3.976 in)
8 mm (0.314 in)
4WD Expedition with rear coil spring suspension 101 mm (3.976 in)
8 mm (0.314 in)
8 mm (0.314 in)
4WD Expedition EL with rear coil spring suspension 101 mm (3.976 i
8 mm (0.314 in)
4WD Navigator with rear coil spring suspension 98 mm (3.858 in)
8 mm (0.314 in)
RWD Navigator with rear coil spring suspension 99 mm (3.897 in)
8 mm (0.314 in)
4WD Navigator L with rear coil spring suspension 100 mm (3.937 in)
8 mm (0.314 in)
RWD Navigator L with rear coil spring suspension 101 mm (3.976 in)
8 mm (0.314 in)
Expedition with rear air suspension 99 mm (3.897 in)
8 mm (0.314 in)
Expedition EL with rear air suspension 99 mm (3.897 in)
8 mm (0.314 in)
Navigator with rear air suspension 99 mm (3.897 in)
8 mm (0.314 in)
Navigator L with rear air suspension 99 mm (3.897 in)
8 mm (0.314 in)
Vehicle Leao-Side Differences)
Front ride height - maximum (with coil spring 12 mm (0.472 in)
suspension)
Rear ride height - maximum 7 mm (0.275 in)

Lower arm forward and rearward nuts (front) 350 258
Stabilizer bar bracket nuts 55 41
Stabilizer bar link lower nuts 80 59
Tie-rod end jam nuts (front) 103 76
Toe link cam bolt nuts (rear) 275 203
Upper arm-to-frame bolts (rear) 225 166

SECTION 204-00: Suspension System - General 2011 Expedition, Navigator Workshop

Information Manual
Wheel Alignment Angles
The front caster and camber are adjusted by removing the lower arm front and rear bolts and installing
adjuster kits to allow the arm to be adjusted in the frame slots. Front toe is adjusted by the use of the front
wheel knuckle tie rods. The rear camber is adjusted by removing the upper arm camber set shim or shim pins
to allow the arm to be adjusted in the frame slot. The rear toe is adjusted by the use of the rear toe link cam
bolt and nut.
Camber
Negative and Positive Camber
Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and
has a direct affect on tire wear.
Caster
Item Description
1 Positive caster
2 True vertical
3 Steering axis
Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the
side. The caster specifications in this section will give the vehicle the best directional stability characteristics
when loaded and driven. The caster setting does not affect tire wear.
Toe
Wheel Alignment Angles 1710

Positive Toe (Toe In)
Negative Toe (Toe Out)
The vehicle toe setting:
affects tire wear and directional stability.

must be checked after adding aftermarket equipment, such as a snowplow.
Wander
Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to
maintain a straight path down a level road.
Shimmy
Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel resulting
from large, side-to-side (lateral) tire/wheel movements.
Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts
pot holes or irregularities in the road surface.
Nibble
Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road
surfaces or tire imbalance. This condition is observed by the driver as small rotational oscillations of the
steering wheel. For information on wheel and tire diagnosis, refer to Section 204-04 .
Poor Returnability/Sticky Steering
Poor returnability and sticky steering is used to describe the poor return of the steering wheel to center after a
turn or when the steering correction is completed.
Drift/Pull
Positive Toe (Toe In) 1711

Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle
going straight.
Drift describes what a vehicle with this condition does with hands off the steering wheel.
A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead
path and require constant steering input in the opposite direction to counteract the effect.
Drift/pull may be induced by conditions external to the vehicle (such as wind or road camber).
Poor Groove Feel
Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as the wheel
is rocked slowly left and right within very small turns around center or straight-ahead (under 20 degrees of
steering wheel turn). Efforts may be said to be "flat on center."
Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of gear teeth
in the steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from
the self-aligning forces at the road wheel or tire patch.
In the diagnosis of a steering or alignment concern, it is important to understand the difference
between wander and poor groove feel.
Negative Toe (Toe Out) 1712


SECTION 204-00: Suspension System - General Information
Manual
Suspension System
1. Road test.
If any suspension alignment or ride height concerns are present, GO to Symptom Chart -
Suspension System .
Verify the customer concern by carrying out a road test on a smooth road. If any vibrations
are present, refer to GO to Symptom Chart - NVH .
2. Inspect tires.
Check the tire pressure with all normal loads in the vehicle and with the tires cold. Refer to
the Vehicle Certification (VC) label.
Verify that all tires are sized to specification. Refer to Section 204-04 .
Inspect the tires for incorrect wear and damage. Refer to Section 204-04 .
3. Inspect chassis and underbody.

Remove any excessive accumulation of mud, dirt or road deposits from the chassis and
underbody.
4. Inspect for aftermarket equipment.

Check for aftermarket changes to the steering, suspension, wheel and tire components (such
as competition, heavy duty, etc.). The specifications shown in this manual do not apply to
vehicles equipped with aftermarket equipment.
Mechanical
Front wheel bearing(s)

Loose or damaged front or rear suspension
components
Loose, damaged or missing suspension
fastener(s)
Loose or damaged leaf spring shackle(s)
Incorrect spring usage
Damaged or sagging spring(s)
Damaged or leaking shock absorber(s)
Worn or damaged suspension bushing(s)
Loose, worn or damaged steering system
components
Damaged axle components
5. If an obvious cause for an observed or reported condition is found, correct the cause (if possible)
before proceeding to the next step.
Poor Groove Feel 1713

6. If the fault is not visually evident, GO to Symptom Chart - Suspension System or GO to Symptom
Chart - NVH .
Symptom Chart - Suspension System
Symptom Chart - Suspension System
Symptom Chart - NVH
Symptom Chart - NVH

Squeak or grunt - noise from the front suspension, occurs more in cold ambient temperatures. More
noticeable over rough roads or when turning
Front stabilizer bar insulators
Under these conditions, the noise is acceptable. CHECK TSBs.
Clunk - noise from the front suspension, occurs in and out of turns
Loose front shocks
INSPECT for shock absorber fasteners. TIGHTEN to specifications. Refer to the appropriate section
in Group 204 for the procedure.
Clunk - noise from the rear suspension, occurs when shifting from REVERSE to DRIVE
Loose or damaged rear suspension components
INSPECT for loose or damaged rear suspension components. REPAIR or INSTALL new components
as necessary. Refer to the appropriate section in Group 204 for the procedure.
Click or pop - noise from the front suspension. More noticeable over rough roads or over bumps
Worn or damaged ball joint(s)
INSPECT the front ball joints. REFER to the Ball Joint Inspection Component Test in this section.
INSTALL new ball joints as necessary.
Front suspension noise - a squeak, creak or rattle noise. Occurs mostly over bumps or rough roads
Loose or bent front shock absorber(s)
Suspension System 1714

Damaged spring or spring mount(s)

Damaged or worn control/radius arm bushing(s)
Worn or damaged stabilizer bar bushings or link(s)
INSPECT the front suspension. INSTALL new components as necessary. Refer to the appropriate
Rear suspension noise - a squeak, creak or rattle noise. Occurs mostly over bumps or rough roads
Loose or bent rear shock absorber(s)

Damaged spring or spring mount(s)
Damaged or worn bushing(s)
Worn or damaged stabilizer bar bushing(s) or link(s)
INSPECT the rear suspension. INSTALL new components as necessary. Refer to the appropriate
Shudder - occurs during acceleration from a slow speed or stop
Incorrect ride height causing incorrect driveline angle
REFER to Section 205-00 for driveline angle diagnosis.
Shimmy
Loose wheel nut(s)
TIGHTEN the nut(s) to specification. REFER to Section 204-04 .
Loose front suspension fastener(s)
TIGHTEN the fastener(s) to specification. Refer to the appropriate section in Group 204 for the
procedure.
Loose front wheel bearing(s)
INSPECT the front wheel bearing(s). Refer to the appropriate section in Group 204 for the procedure.
INSTALL new bearing(s) as necessary.
Shock absorber(s)
INSTALL new shock absorbers as necessary. Refer to the appropriate section in Group 204 for the
procedure.
Shimmy - most noticeable on coast/deceleration. Also hard steering condition
Excessive positive caster
CHECK the front caster and ADJUST as necessary. REFER to Camber and Caster Adjustment - Front
in this section.
Rough/harsh ride
Shock absorber(s)
Suspension System 1715

INSTALL new shock absorber(s) as necessary. Refer to the appropriate section in Group 204 for the
procedure.
Spring(s)
INSTALL new spring(s) as necessary. Refer to the appropriate section in Group 204 for the
procedure.
Pinpoint Test A: Vehicle Drifts/Pulls

Unevenly loaded vehicle
Tire pressure
Tire forces
Brake drag
Incorrect vehicle alignment
Steering system
PINPOINT TEST A: VEHICLE DRIFTS/PULLS

A1 CHECK FOR UNEVENLY LOADED
VEHICLE
Yes
Visually check the vehicle for an uneven ADVISE the customer of uneven loading condition.
loading condition.
Is the vehicle unevenly loaded? No
GO to A2 .
A2 CHECK THE TIRE PRESSURES AND
TIRE CONDITIONS
Yes
Check the tire pressures. Refer to the GO to A3 .
Vehicle Certification (VC) label located on
the driver door jamb. Check the tires for No
uneven/abnormal wear. Refer to Diagnosis ADJUST the tire pressures to the specified pressure
and Testing - Wheels and Tires in Section or INSTALL new tires as necessary.
204-04 .
Are the tire pressures and tire
conditions OK?
A3 ISOLATE TIRE DRIFT/PULL
CONDITION
Yes
Cross the front wheel and tire assemblies If the vehicle drifts/pulls in the opposite direction,
from left-to-right. Refer to Section 204-04 tire forces are causing the drift/pull. ROTATE the
. wheel and tire assemblies front-to-rear. REFER to
Does the vehicle drift/pull? Section 204-04 . If the vehicle drifts/pulls in the
same direction, GO to A4 .
No
PINPOINT TEST A: VEHICLE DRIFTS/PULLS 1716

Tire forces were causing the drift/pull and the

concern has been corrected.
A4 CHECK FOR BRAKE DRAG
Yes
Spin all 4 wheel and tire assemblies by GO to A5 .
hand and check for brake drag.
Do the wheels spin freely? No
REFER to Section 206-00 to diagnose brake drag
condition.
A5 CHECK THE WHEEL ALIGNMENT
Yes
Using alignment equipment and the ADJUST the alignment as necessary. REFER to
manufacturer's instructions, check the General Procedures in this section.
wheel alignment.
Is the wheel alignment out of No
specification? REFER to Section 211-00 to diagnose steering
system drift/pull/wander condition.
Component Tests
Ball Joint Inspection
1. Prior to inspecting the ball joints for wear, inspect the wheel bearings. Refer to Section 100-04 .
2. WARNING: Any air spring which is unfolded must be refolded prior to being installed in a
vehicle. Refer to the procedure in this section. An incorrectly folded air spring could rupture,
altering the handling characteristics of the vehicle. If a vehicle has been driven with an
incorrectly folded air spring, a new air spring must be installed. Failure to follow these
instructions may result in serious injury to vehicle occupant(s).
NOTE: In order to obtain accurate measurements, the suspension must be in full rebound with the
weight of the vehicle supported by the frame.
Raise and support the vehicle by the frame to allow the wheels to hang in the rebound position.
3. Inspect the ball joint and ball joint boot for damage.
If the ball joint or ball joint boot is damaged, install a new ball joint as necessary. Refer to
Section 204-01A for Rear Wheel Drive (RWD) vehicles and Section 204-01B for Four-Wheel
Drive (4WD) vehicles.
NOTE: Carry out Steps 4-6 to inspect the lower ball joint. Carry out Steps 7-9 to inspect the upper ball joint.
4. NOTICE: Do not use any tools or equipment to move the wheel and tire assembly or suspension
components while checking for relative movement. Suspension damage may occur. The use of
tools or equipment will also create relative movement that may not exist when using hand force.
Relative movement must be measured using hand force only.
NOTE: The weight of the wheel and tire assembly must be overcome to obtain an accurate
measurement on the dial indicator.
Inspect the ball joint for relative movement by alternately pulling downward and pushing upward on
the wheel and tire assembly by hand. Note any relative vertical movement between the wheel knuckle

and lower arm at the lower ball joint.
If relative movement is not felt or seen, the ball joint is OK. Do not install a new ball joint.
If relative movement is found, continue with Step 5.
5. NOTE: In order to obtain an accurate measurement, the dial indicator should be aligned as close as
possible with the vertical axis (center line) of the ball joint.
To measure ball joint deflection, attach a suitable dial indicator with a flexible arm between the lower
control arm and the wheel knuckle or ball joint stud.
6. Measure the ball joint deflection while an assistant pushes up and pulls down on the wheel and tire
assembly by hand.
If the deflection exceeds the specification, a new ball joint must be installed. Refer to Section
204-01A for RWD vehicles and Section 204-01B for 4WD vehicles.
If the deflection meets the specification, continue with the procedure.
7. NOTICE: Do not use any tools or equipment to move the wheel and tire assembly or suspension
components while checking for relative movement. Suspension damage may occur. The use of
tools or equipment will also create relative movement that may not exist when using hand force.
Relative movement must be measured using hand force only.
Inspect the ball joint for relative movement by alternately pulling downward and pushing upward on
the upper control arm by hand. Note any relative vertical movement between the wheel knuckle and
upper arm at the upper ball joint.
If relative movement is not felt or seen, the ball joint is OK. Do not install a new ball joint.
If relative movement is found, continue with Step 8.
8. NOTE: In order to obtain an accurate measurement, the dial indicator should be aligned as close as
possible with the vertical axis of the ball joint.
To measure ball joint deflection, attach a suitable dial indicator with a flexible arm between the upper
control arm and the wheel knuckle or ball joint stud.

9. Measure the ball joint deflection while an assistant pushes up and then pulls down on the upper
control arm by hand.
If the deflection exceeds the specification, a new ball joint must be installed. For additional
information, refer to Section 204-01A for RWD vehicles and Section 204-01B for 4WD
vehicles.
If the deflection meets the specification, no further action is required.


Manual
Ride Height Measurement
Front Ride Height Measurement
Item Description
1 Ride height = 2 - 3
2 Measurement 2
3 Measurement 3
NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the correct
pressure. Vehicle should have a full tank of fuel.
start="1">
Position a suitable surface gauge (such as Starrett 57D Surface Gauge), on a flat, level surface and adjust
the gauge's arm until the scriber point is located in the center of the lower arm rearward bolt.
Lock the surface gauge in this position.
2. With the surface gauge positioned on a flat, level surface, record the measurement of the surface
gauge position (measurement 2).
3. Position the surface gauge on the same flat, level surface as used in Step 1, adjust the gauge's arm
until the scriber point is located on the lower surface of the wheel knuckle near the ball joint.
Ride Height Measurement 1720

Lock the surface gauge in this position.
4. With the surface gauge positioned on a flat, level surface, record the measurement of the surface
gauge position (measurement 3).
5. Subtract measurement 3 from measurement 2 to obtain the front ride height.

For additional information, refer to Specifications in this section.
Rear Ride Height Measurement
Item Description
1 Ride height = 2 - 3
2 Measurement 2
3 Measurement 3
NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the correct
pressure. Vehicle should have a full tank of fuel.
1. Measure the distance between the flat level surface and the center of the lower arm rearward bolt
(measurement 2).
2. Measure the distance between the flat level surface and the center of the shock absorber lower bolt
(rearward side) (measurement 3).
3. Subtract measurement 3 from measurement 2 to obtain the rear ride height.

For additional information, refer to Specifications in this section.



Manual
Camber and Caster Adjustment - Front
NOTICE: Do not remove the stabilizer bar brackets until the stabilizer links have been disconnected or
damage to the stabilizer bar links may occur.
NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the caster, camber
or toe. For additional information, refer to Section 204-05 .
NOTE: To allow for adjustment of the lower arm in the frame slots, the lower arm bolts and nuts must be
removed and discarded. They are replaced with cam bolt kit 3C333. The vehicle should be supported by the
frame to ease movement of the lower arm in the slot.
1. Using alignmement and the manufacturers instructions, measure the front caster and camber.
Refer to Alignment Specifications in the Specifications portion of this section for optimal
alignment settings.
If the caster and camber values are not within specification, go to the next step.
2. Remove and discard the lower arm front and rear nuts and bolts.
3. NOTICE: Do not hold the stabilizer link boot with any tool, as damage to the boot will occur.
NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nuts.
Remove and discard the stabilizer bar link lower nuts.
4. Remove the 4 stabilizer bar bracket nuts, 2 stabilizer bar brackets and position the stabilizer bar aside.
Camber and Caster Adjustment - Front 1723

5. Remove the stabilizer bar bracket bolts and plate assembly.
6. Install the front cam bolt kit and loosely install the nut.
7. Install the rear cam bolt kit and loosely install the nut.
8. To adjust the caster and camber, refer to the following chart.

Adjustments that require moving the front and the rear of the lower arm should be made
equally.
Adjustment Front of Lower Arm Rear of Lower Arm

Increase caster In Out
Decrease caster Out In
Increase camber In In
Decrease camber Out Out
Increase caster and camber simultaneously In -
Decrease caster and camber simultaneously Out -
9. With the weight of the vehicle resting on the wheel and tire assemblies, hold the front cam bolt and
tighten the nut to 350 Nm (258 lb-ft).

10. With the weight of the vehicle resting on the wheel and tire assemblies, hold the rear cam bolt and
tighten the nut to 350 Nm (258 lb-ft).
11. Install the 2 stabilizer bar bracket bolts and plate assembly.
12. Position the stabilizer bar, install the 2 stabilizer bar brackets and the 4 stabilizer bar bracket nuts.
Tighten the nuts to 55 Nm (41 lb-ft).
13. NOTICE: Do not hold the stabilizer link boot with any tool, as damage to the boot will occur.
NOTE: Use the hex-holding feature to prevent the stud from turning while installing the nuts.
Install the 2 stabilizer bar link lower nuts.
Tighten the nuts to 80 Nm (59 lb-ft).
14. Check and, if necessary, adjust the front toe. For additional information, refer to Toe Adjustment -
Front in this section.



Manual
Toe Adjustment - Front
NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the caster, camber
or toe. For additional information, refer to Section 204-05 .
1. Using alignment equipment and the manufacturer's instructions, measure the front toe.
alignment settings.
If the front toe values are not within specification, go to the next step.
2. Start the engine and center the steering wheel.
3. Turn the engine off and, using a suitable swheel holding device, lock the steering wheel in the
4. Remove the steering gear bellows clamp(s).
5. Loosen the tie-rod end jam nut(s).
6. NOTE: Do not allow the steering gear bellows to twist while rotating the tie rod.
Rotate the tie rod(s) to achieve the desired toe setting.
7. NOTICE: Make sure to hold the tie-rod end stationary while tightening the jam nut or damage
to the boot may occur.
NOTE: Make sure that the toe settings are not disturbed while tightening the jam nuts.
Toe Adjustment - Front 1727

Tighten the tie-rod end jam nut(s) to 103 Nm (76 lb-ft).
8. Install the steering gear bellows clamp(s).
Toe Adjustment - Front 1728


Manual
Camber Adjustment - Rear
NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the rear camber or
toe. For additional information, refer to Section 204-05 .
NOTE: Before carrying out a camber adjustment, check the tires for the correct pressure. Inspect the tires for
incorrect wear or damage. Inspect the suspension for wear or damage.
1. Using alignment equipment and the manufacturer's instructions, measure the rear camber.
alignment settings.
If the rear camber value is not within specn, go to the next step.
2. Remove the upper arm-to-frame bolt and the camber set shim.
Discard the camber set shim.
Install and snug the upper arm-to frame bolt.
3. Position the upper arm-to-frame bolt in the upper arm-to-frame slot until the camber setting is within
specification.
4. NOTE: Do not allow the upper arm to move and change the camber adjustment setting when
tightening the bolt.
Tighten the upper arm-to-frame bolt to 225 Nm (166 lb-ft).
5. Recheck the camber setting, adjust as necessary.
6. Check and, if necessary, adjust the rear toe. For additional information, refer to Toe Adjustment -
Rear in this section.
Camber Adjustment - Rear 1729

Camber Adjustment - Rear 1730


Manual
Toe Adjustment - Rear
NOTE: Air suspension vehicles must be at trim ride height prior to measuring or adjusting the rear toe. For
NOTE: Before carrying out a toe adjustment, check the tires for the correct pressure. Inspect the tires for
incorrect wear or damage. Inspect the suspension for wear or damage.
1. Using alignment equipment and the manufacturer's instructions, measure the rear toe.
alignment settings.
If the rear toe values are not within specification, go to the ne
2. Loosen the toe link cam bolt nut(s).
3. Rotate the toe link cam bolt(s) until the toe setting is within specification.
4. NOTE: Make sure the toe settings are not disturbed while tightening the cam nut(s).
Tighten the toe link cam bolt nut(s) to 275 Nm (203 lb-ft).
5. Recheck the rear toe setting, adjust as necessary.
Toe Adjustment - Rear 1731


SECTION 204-01A: Front Suspension - Rear Wheel Drive 2011 Expedition, Navigator Workshop
(RWD) Manual

Brake caliper anchor plate bolts 250 184 -
Brake disc shield bolts 17 - 150
Brake flexible hose bracket bolt 30 22 -
Lower arm forward and rearward nuts 350 258 -
Lower ball joint nut 150 111 -
Shock absorber lower nut 550 406 -
Shock absorber upper mount nuts 40 30 -
Shock rod nut 56 41 -
Stabilizer bar bracket nuts 55 41 -
Stabilizer bar link upper and lower nuts 80 59 -
Tie-rod end nut 115 85 -
Upper arm-to-frame nuts 150 111 -
Upper ball joint nut 115 85 -
Wheel bearing and wheel hub bolts 175 129 -
Wheel speed sensor bolt 18 159
Wheel speed sensor harness bracket bolt 12 - 106


SECTION 204-01A: Front Suspension - Rear Wheel Drive (RWD)
Workshop Manual
Front Suspension
The Rear Wheel Drive (RWD) front suspension consists of the following components:
Upper control arms

Lower control arms
Shock absorbers
Springs
Wheel knuckles
Wheel bearings and wheel hubs
Stabilizer bar and links
The vehicle can be equipped with either a vehicle dynamic suspension (using air springs in the rear of the
vehicle) or a standard suspension (using coil springs at all 4 corners of the vehicle). Both are an
independent-type front suspension which utilize a stabilizer bar to aid in vehicle stability. The wheel hub and
wheel bearing are sealed units and are serviced as assemblies. The lower ball joints can be serviced
independently from the lower arms.
Front Suspension 1734

(RWD) Manual
Front Suspension

(RWD) Manual
Wheel Bearing and Wheel Hub

1 - Brake caliper and anchor plate
assembly
2 1125 Brake disc
3 W710279 Wheel speed sensor bolt
4 2C204 Wheel speed sensor
5 2B663 Wheel bearing and wheel hub
6 W707292 Brake caliper anchor plate bolt
(2 required)
7 W707353 Wheel bearing and wheel
hub bolt (4 required)
NOTICE: Suspension fasteners are critical parts because they affect performance of vital components
and systems and their failure may result in major service expense. New parts must be installed with the
same part numbers or equivalent parts, if replacement is necessary. Do not use a replacement part of
lesser quality or substitute design. Torque values must be used as specified during reassembly to make
sure of correct retention of these parts.
1. Disconnect the wheel speed sensor electrical connector.
2. Remove the wheel and tire. For additional information, refer to Section 204-04 .
3. Remove the wheel speed sensor harness bracket bolt and detach the harness from the retainers.
Wheel Bearing and Wheel Hub 1736

4. NOTICE: Do not allow the caliper and anchor plate assembly to hang from the brake hose or
damage to the hose may result.
Remove the 2 bolts and position the caliper and anchor plate aside.
Support the caliper using mechanic's wire.

5. Remove the brake disc.
6. Remove the 4 bolts and the wheel bearing and wheel hub.
Discard the bolts.
7. If installing a new wheel bearing and wheel hub, remove the wheel speed sensor bolt and the wheel
speed sensor.
8. NOTICE: If the original wheel bearing and wheel hub is being installed, a new O-ring seal must
be installed or damage to the wheel bearing may occur.

(RWD) Manual
Wheel Studs
Special Tool(s)
C-Frame and Screw Assembly

211-023 (T74P-3044-A1)

1 - Brake calid anchor plate assembly
2 1125 Brake disc
3 W707287 Wheel stud
4 W707353 Brake caliper anchor plate bolt (2 required)
Removal
2. NOTICE: Do not allow the brake caliper and anchor plate assembly to hang from the brake
hose or damage to the hose may result.
Remove the 2 bolts and position the brake caliper and anchor plate assembly aside.
Support the brake caliper and anchor plate assembly using mechanic's wire.
4. Using the C-Frame and Screw Assembly, remove the wheel stud.
Wheel Studs 1738

Installation
1. NOTE: Make sure to use washers that have an ID that is larger than the OD of the wheel stud
serrations. Use enough washers (approximately 4) to allow the wheel stud to fully seat against the hub
flange.
Position the new wheel stud in the wheel hub, aligning the serrations in the wheel hub flange made by
the original wheel stud.
Place 4 washers over the outside end of the wheel stud and thread a standard wheel nut onto
the wheel stud with the flat side against the washers.
Tighten the wheel nut until the wheel stud head seats against the back side of the wheel hub
flange.
2. Remove the wheel nut and washers.
3. Install the brake disc.
4. Position the brake caliper and anchor plate assembly and install the bolts.
Tighten the bolts to 250 Nm (184 lb-ft).
5. Install the wheel and tire. For additional information, refer to Section 204-04 .
Wheel Studs 1739

Wheel Studs 1740

(RWD) Manual
Lower Arm
Special Tool(s)
Separator, Ball Joint

204-592

1 3051 LH/ 3042 RH Lower arm
2 W707254 Lower ball joint nut
3 W711399 Lower arm forward bolt
4 W711310 Lower arm forward nut
5 W712682 Shock absorber lower bolt
6 W520217 Shock absorber lower nut
7 N807144 Stabilizer bar link lower nut
8 W709877 Lower arm rearward bolt
9 W711310 Lower arm rearward nut
Removal
Lower Arm 1741

1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a level,
static ground position (curb height).
3. NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nut.
Remove and discard the stabilizer bar link lower nut.
4. Remove and discard the lower ball joint nut.
5. NOTICE: Make sure to use the Ball Joint Separator when separating the lower ball joint from
the knuckle to prevent damage to the ball joint boot.
Using the Ball Joint Separator, separate the ball joint from the knuckle.
6. Remove and discard the lower arm rearward nut and bolt.
7. Remove and discard the lower arm forward nut and bolt.
8. Remove the shock absorber lower nut, bolt and the lower arm.
Discard the shock absorber lower nut and bolt.
Installation
1. Position the lower arm and loosely install the new shock absorber lower bolt and nut.
2. Loosely install the new lower arm forward nut and bolt.
3. Loosely install the new lower arm rearward nut and bolt.
4. Position the lower ball joint into the wheel knuckle and install the new lower ball joint nut.
5. Install the new stabilizer bar link lower nut.

6. Use a suitable jack to raise the suspension until the distance between the center of the hub and the lip
of the fender is equal to the measurement taken in Step 1 (curb height).
Lower Arm 1742

7. NOTE: Use a crowfoot wrench to tighten the lower arm rearward nut.
Tighten the lower arm rearward nut to 350 Nm (258 lb-ft).
8. Tighten the lower arm forward nut to 350 Nm (258 lb-ft).
9. Tighten the shock absorber lower nut to 550 Nm (406 lb-ft).
11. Check and, if necessary, align the front end. For additional information, refer to Section 204-00 .
Lower Arm 1743

(RWD) Manual
Upper Arm
Special Tool(s)

204-592
Part Number Description

1 3091 LH/ 3084 RH Upper arm
2 W520215 Upper ball joint nut
3 W520215 Upper arm-to-frame nuts (2 required)
4 W707841 Upper arm-to-frame bolts (2 required)
Removal
1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a level,
static ground position (curb height).
2. Remove the shock absorber and spring assembly. For additional information, refer to Shock Absorber
and Spring Assembly in this section.
Upper Arm 1744

3. Remove and discard the upper ball joint nut.
4. Using the Ball Joint Separator, separate the upper ball joint from the wheel knuckle.
5. Remove the upper arm-to-frame nuts and bolts and the upper arm.
Discard the bolts.
Installation
1. NOTE: Do not tighten the nuts at this time.
Position the upper arm and loosely install the new upper arm-to-frame bolts and nuts.
2. Position the ball joint into the wheel knuckle and install the new upper ball joint nut.
4. Tighten the upper arm-to-frame nuts to 150 Nm (111 lb-ft).
5. Install the shock absorber and spring assembly. For additional information, refer to Shock Absorber
and Spring Assembly in this section.
Upper Arm 1745

Upper Arm 1746

(RWD) Manual
Stabilizer Bar and Link
NOTE: LH side shown, RH side similar.

1 W520213 Stabilizer bar bracket nut (4 required)
2 3B353 Stabilizer bar bracket (2 required)
3 5484 Stabilizer bar bushing (2 required)
4 5494
5 5K483 Stabilizer bar link (2 required)
6 W520214-S440 Stabilizer bar link lower nut (2 required)
7 W520214-S440 Stabilizer bar link upper nut (2 required)
8 W711583 Stabilizer bracket bolt plate
100-02 .
2. NOTE: The hex-holding feature can be used to prevent turning of the stud while removing the nut.
Remove and discard the 2 stabilizer bar link upper nuts.
To install, tighten the new nuts to 70 Nm (52 lb-ft).
3. NOTICE: Do not hold the stabilizer link boot with any tool as damage to the boot will occur.
NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nut.
Stabilizer Bar and Link 1747

Remove and discard the 2 stabilizer bar link lower nuts and remove the 2 stabilizer bar links.
4. Remove the 4 stabilizer bar bracket nuts, brackets and the stabilizer bar.
Discard the nuts.
5. Remove and discard the stabilizer bracket bolt plates.
6. NOTE: Make sure the stabilizer bar bushing upset is installed into the bracket groove.
Inspect and, if necessary, install new stabilizer bar bushings.

(RWD) Manual
Wheel Knuckle
Special Tool(s)

204-592

1 N807144 Stabilizer bar link lower nut
4 W520215 Tie-rod end nut
7 3K186 LH/ 3K185 Wheel knuckle
RH
8 W505252 Brake disc shield bolts (3 required)
9 2K005 LH/ 2K004 Brake disc shield
RH
10 W710279 Wheel speed sensor harness bracket bolt
11 - Wheel speed sensor harness bracket (part of
2C204)
Removal
Wheel Knuckle 1749

1. Remove the wheel bearing and wheel hub. For additional information, refer to Wheel Bearing and
Wheel Hub in this section.
2. Remove and discard the tie-rod end nut.
3. Using the Ball Joint Separator, separate the tie-rod end from the wheel knuckle.
4. Remove the wheel speed sensor harness bracket bolt and position the harness aside.
6. Remove and discard the shock absorber lower nut and bolt.
8. NOTE: Be sure not to damage the ball joint boot when installing the Ball Joint Separator.
Using the Ball Joint Separator, separate the upper ball joint from the wheel knuckle.
Using the Ball Joint Separator, separate the lower ball joint from the wheel knuckle.
Wheel Knuckle 1750

11. If necessary, remove the 3 brake disc shield bolts and remove the brake disc shield.
Installation
NOTICE: Do not tighten the lower shock nut until the installation procedure is complete and the weight
of the vehicle is resting on the wheel and tire assemblies or incorrect clamp load and bushing damage
may occur.
1. If necessary, install the brake disc shield and the 3 brake disc shield bolts.
2. Position the lower ball joint into the wheel knuckle and install the new lower ball joint nut.
3. Position the upper ball joint into the wheel knuckle and install the new upper ball joint nut.
4. NOTE: Do not tighten the nut at this time.
Loosely install the new shock absorber lower nut and bolt.
5. NOTE: Use the hex-holding feature to prevent the stud from turning while installing the nut.
Position the stabilizer bar link and install the new stabilizer bar link lower nut.
6. Position the wheel speed sensor harness bracket and install the wheel speed sensor harness bracket
bolt.
7. Position the tie-rod end and install the new tie-rod end nut.
8. Install the wheel bearing and wheel hub. For additional information, refer to Wheel Bearing and
9. With the weight of the vehicle on the wheel and tire, tighten the shock absorber lower nut to 550 Nm
(406 lb-ft).
Wheel Knuckle 1751

Wheel Knuckle 1752

(RWD) Manual
Shock Absorber and Spring Assembly
Special Tool(s)

204-592

1 18B036 Shock absorber and spring assembly
5 W712334 Shock absorber upper mount nuts (3 required)
7 W712134 Shock rod nut
8 5310 Spring
9 18A099 Upper mount
10 18A154 Insulator
11 18A047 Dust boot
Shock Absorber and Spring Assembly 1753

12 18045 Shock absorber

13 - Brake flexible hose retainer (part of 2078)
14 W611633 Brake flexible hose bracket bolt
Removal
1. Remove and discard the shock absorber upper mount nuts.
5. Detach the flexible hose retainer from the speed sensor harness.
6. Remove the brake flexible hose bracket bolt and disconnect the bracket from the wheel knuckle.
9. Using the Ball Joint Separator, disconnect the upper arm ball joint from the wheel knuckle and
remove the shock absorber and spring assembly.
10. NOTE: If the individual spring and/or shock components are not being serviced, continue to the
Installation procedure.
NOTE: For reference during assembly, index-mark the upper mount, spring and shock absorber.
Using a suitable spring compressor, compress the spring until the tension is released from the shock
absorber.

11. NOTE: Use the hex-holding feature to prevent the shock rod from turning while removing the nut.
While holding the shock rod, remove the nut and the shock absorber.
Discard the nut.
12. Remove the upper mount, dust boot and insulator.
Installation
may occur.
1. Position the shock absorber and spring and install the dust boot, insulator and the upper mount.
2. NOTE: Align the index marks made during disassembly.
absorber.
3. NOTE: Use the hex-holding feature to prevent the shock rod from turning while installing the nut.
Using the hex-holding feature to hold the shock rod, install the shock absorber and the shock rod nut.

Tighten the new nut to 56 Nm (41 lb-ft).
4. Install the shock absorber and spring assembly and connect the upper arm ball joint to the wheel
knuckle.
Tighten the new nut to 115 Nm (85 lb-ft).
6. Connect the brake flexible hose bracket to the wheel knuckle and install the bolt.
Tighten the bolt to 30 Nm (22 lb-ft).
7. Attach the flexible hose retainer to the speed sensor harness.
8. Install the tie-rod end nut.

10. Install the new shock absorber upper mount nuts.

(406 lb-ft).

(RWD) Manual
Ball Joint - Lower
Special Tool(s)
Installer/Remover, Ball Joint

204-358
Installer/Remover, C-Frame and Scr205-086
Remover, Ball Joint

204-182

1 3050 Lower ball joint
2 3K050 Lower ball joint snap ring (also part of 3050 kit)
Removal
1. Remove the wheel knuckle. For additional information, refer to Wheel Knuckle in this section.
2. Remove and discard the lower ball joint snap ring.
3. Using the C-Frame and Screw Installer/Remover and the Ball Joint Remover, remove the lower ball
joint.
Ball Joint - Lower 1757

Installation
1. NOTICE: Do not damage the lower ball joint boot when installing the C-Frame and Screw
Installer/Remover and the Ball Joint Installer/Remover or premature failure of the ball joint
may occur.
NOTE: Make sure the ball joint snap ring is fully seated.
Using the C-Frame and Screw Installer/Remover and the Ball Joint Installer/Remover, install the
lower ball joint.
Install the ball joint snap ring.
2. Install the wheel knuckle. For additional information, refer to Wheel Knuckle in this section.

SECTION 204-01B: Front Suspension - Four Wheel Drive 2011 Expedition, Navigator Workshop
(4WD) Manual

Halfshaft nut 27 20 -
Integrated Wheel End (IWE) bolts 15 - 133
Lower arm forward and rearward nuts 350 258align="top" align="center">-
Shock absorber lower nut 550 406 -
Shock absorber upper nuts 40 30 -
Stabilizer bar bracket nuts 55 41 -
Stabilizer bar link upper and lower nuts 80 59 -
Upper arm-to-frame nuts 150 111 -
Wheel bearing and wheel hub bolts 175 129 -
Wheel speed sensor bolp" align="center">18 - 159

(4WD) Manual
Front Suspension
The Four-Wheel Drive (4WD) front suspension consists of the following components:
Upper control arms

Lower control arms
Shock absorbers
Springs
Wheel knuckles
Wheel bearing and wheel hubs
vehicle) or a standard suspension (using coil springs at all 4 corners of the vehicle). Both are an
independent-type front suspension which utilize a stabilizer bar to aid in vehicle stability. The wheel hub and
wheel bearing are sealed units and are serviced as an assemblies. The lower ball joints can be serviced
independently from the lower arm.
For information on the vehicle dynamic suspension system, refer to Section 204-05 .

(4WD) Manual
Front Suspension

(4WD) Manual

1 - Brake caliper and anchor plate assembly
2 1125 Brake disc
3 1131 Dust cap
4 N808405 Halfshaft nut
7 W707353 Wheel bearing and wheel hub bolt (4 required)
8 2C204 Wheel speed sensor
9 W710279 Wheel speed sensor bolt
10 - Wheel speed sensor harness bracket bolt (part of
2C204)
11 - O-ring seal (part of 2B663)

3. Remove the wheel speed sensor harness bracket bolt and detach the harness from the retainers.
4. NOTICE: Do not allow the caliper to hang from the brake hose or damage to the hose may
result.
Remove the 2 bolts and position the brake caliper and anchor plate assembly aside.
Support the brake caliper and anchor plate assembly using mechanic's wire.
6. Remove the halfshaft nut dust cap.
7. Remove and discard the halfshaft nut.

To install, tighten the new nut to 27 Nm (20 lb-ft).
8. Remove the 4 bolts and the wheel bearing and hub.

Discard the bolts.
To install, tighten the new bolts to 175 Nm (129 lb-ft).
9. If installing a new wheel bearing and wheel hub, remove the wheel speed sensor bolt and the wheel
speed sensor.
10. NOTICE: If the original wheel bearing and wheel hub is being installed, install a new wheel hub
O-ring seal or damage to the wheel bearing may occur.
NOTICE: Verify the spline engagement by checking for spline lash before installing the
halfshaft nut or damage to the halfshaft and wheel bearing and hub may occur.


(4WD) Manual
Wheel Studs
For additional information, refer to Section 204-01A .
Wheel Studs 1765

(4WD) Manual
Lower Arm

1 W707254 Lower arm forward nut
2 W707843 Lower arm forward bolt
3 W707202 Lower arm rearward bolt
4 W707254 Lower arm rearward nut
7 3051 LH/ 3042 RH Lower arm
4. Remove and discard the lower arm rearward nut and bolt.
5. Remove and discard the lower arm forward nut and bolt.
6. Remove the shock absorber lower nut, bolt and the lower arm.
Discard the shock absorber lower nut.
7. NOTICE: Do not tighten the lower shock nut, lower arm forward nut or lower arm rearward
nut until the installation procedure is complete and the weight of the vehicle is resting on the
Lower Arm 1766

wheel and tire assemblies.
Installation
Position the lower arm and loosely install the new shock absorber lower bolt and nut.
Loosely install the new lower arm forward nut and bolt.
Loosely install the new lower arm rearward nut and bolt.

6. NOTE: Use a crowfoot wrench to tighten the lower arm rearward nut.
Tighten the lower arm rearward nut to 350 Nm (258 lb-ft).
7. Tighten the lower arm forward nut to 350 Nm (258 lb-ft).
8. Tighten the shock absorber lower nut to 550 Nm (406 lb-ft).
Lower Arm 1767

Lower Arm 1768

(4WD) Manual
Upper Arm
Upper Arm 1769

(4WD) Manual

(4WD) Manual
Wheel Knuckle
Special Tool(s)

204-592

1 N807114 Stabilizer bar link lowut
6 3K186 LH/ 3K185 Wheel knuckle
RH
8 2K005 LH/ 2K004 Brake disc shield
RH
9 W505211 Brake disc shield bolts (3 required)
10 W710279 Integrated Wheel End (IWE) bolts (3 required)
11 - Wheel speed sensor harness bracket (part of
2C204)
12 W710279 Wheel speed sensor harness bracket bolt
Removal
Wheel Knuckle 1771

same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of
2. Remove and discard t tie-rod end nut.
7. Remove the 3 Integrated Wheel End (IWE) bolts.
9. NOTICE: Be sure not to damage the ball joint boot when installing the Ball Joint Separator.
Using the Ball Joint Separator, separate the upper ball joint from the wheel knuckle.
Wheel Knuckle 1772

Using the Ball Joint Separator, separate the lower ball joint from the wheel knuckle and remove the
wheel knuckle.
12. If necessary, remove the 3 brake disc shield bolts and remove the brake disc shield.
Installation
may occur.
NOTICE: When servicing the lower shock nut, take care not to damage the stabilizer link.
1. If necessary, install the brake disc shield and 3 brake disc shield bolts.
2. Position the lower ball joint into the wheel knuckle and install the new nut.
3. Position the upper ball joint and install the new nut.
4. Position the IWE and install the 3 IWE bolts.


7. Position the wheel speed sensor harness bracket and install the bolt.
8. Install the new tie-rod end nut.
Wheel Knuckle 1773

(406 lb-ft).
Wheel Knuckle 1774

(4WD) Manual

(4WD) Manual
Ball Joint - Lower
Special Tool(s)

204-358
Installer/Remover, C-Frame and Screw

205-086
Remover, Ball Joint

204-182

1 3050 Lower ball joint
2 3K050 Lower ball joint snap ring (also part of 3050 kit)
Removal
2. Remove and discard the lower ball joint snap ring.
3. Using the C-Frame and Screw Installer/Remover and Ball Joint Remover, remove the lower ball joint.

Installation
1. NOTICE: Do not damage the lower ball joint boot when installing the C-Frame and Screw
Installer/Remover and Ball Joint Installer/Remover or premature failure of the ball joint may
occur.
NOTE: Make sure the ball joint snap ring is fully seated.
Using the C-Frame and Screw Installer/Remover and Ball Joint Installer/Remover, install the lower
ball joint.
Install the ball joint snap ring.

SECTION 204-02: Rear Suspension 2011 Expedition, Navigator Workshop Manual


Halfshaft nut 300 221 -
Lower arm-to-frame bolt 225 166 -
Lower shock absorber bolt 550 406 -
Lower trailing arm-to-frame bolt 275 203 -
Lower trailing arm-to-wheel knuckle bolt 103 76 -
Shock absorber upper mount nut 40 30 -
Stabilizer bar link nut 63 46 -
Stabilizer bar bracket nut 48 35 -
Toe link-to-frame nut 203 -
Toe link-to-wheel knuckle bolt 225 166 -
Upper arm-to-frame bolt 225 166 -
Upper arm-to-wheel knuckle nut 103 76 -
Upper trailing arm-to-wheel knuckle bolt 250 184 -
Upper trailing arm-to-frame bolt 275 203 -
Wheel bearing and wheel hub bolt 175 129 -
Wheel speed sensor bolt 18 - 159



Rear Suspension
The rear suspension consists of the following components:
Upper arms
Lower arms
Shock absorbers
Springs
Wheel knuckles
Wheel bearing and wheel hub assemblies
Upper trailing arms
Lower trailing arms
Toe links
vehicle) or a standard suspension (using coil springs in the rear of the vehicle). Both are an independent-type
rear suspension which utilize a stabilizer bar to aid in vehicle stability. The wheel hub and wheel bearing
assemblies are sealed units and are serviced as assemblies. The rear suspension has serviceable lower ball
joints and wheel knuckle bushings. The rear suspension also incorporates toe links to adjust the rear toe and a
camber adjustment can be made using camber shims located at the upper arm-to-frame mounts.
For information on the vehicle dynamic suspension, refer to Section 204-05 .
Rear Suspension 1780


Rear Suspension
Rear Suspension 1781



2 W707353 Wheel bearing and wheel hub bolt (4 required)
3 2C204 Rear wheel speed sensor bolt
5 1126 Brake disc
6 - Brake caliper and anchor plate assembly
7 W710084 Halfshaft nut

8 - Rear wheel speed sensor bolt (part of 2C190)
9 2C190 Rear wheel speed sensor
10 - Body harness electrical connector (part of 14A464)
Removal
NOTICE: Suspension fasteners are critical parts because they affect performance of vital parts and
systems and their failure may result in major service expense. New parts must be installed with the
same part numbers or equivalent part, if installation becomes necessary. Do not use a replacement part

of lesser quality or substitute design. Torque values must be used as specified during reassembly to
make sure of correct retention of these parts.
2. NOTE: Have an assistant press the brake pedal to keep the axle from rotating.
Remove and d the halfshaft nut.
3. Using a suitable hub puller, separate the outboard CV joint from the wheel hub.
damage to the hose may result.
Remove the bolts and position the caliper and anchor plate assembly aside.
Support the caliper and anchor plate assembly using mechanic's wire.
6. Detach the wheel speed sensor harness from the retainers and disconnect the wheel speed sensor
electrical connector. Push the wheel speed sensor harness grommet through the brake disc shield.
7. Remove the 4 bolts, the wheel bearing and wheel hub, and the wheel speed sensor as an assembly.
Route the sensor wiring through the access hole in the brake disc shield.
Discard the bolts.
8. If necessary, remove the wheel speed sensor bolt and the wheel speed sensor from the wheel bearing
and wheel hub.
Installation
1. If necessary, install the wheel speed sensor and bolt.

2. Position the wheel bearing and wheel hub, and the wheel speed sensor. Install the 4 new wheel
bearing and wheel hub bolts.
Route the sensor wiring through the access hole in the brake disc shield.
3. Attach the wheel speed sensor harness to the retainers and connect the wheel speed sensor electrical
connector. Push the wheel speed sensor harness grommet through the brake disc shield.
4. Install the brake disc.
5. Position the caliper and anchor plate assembly and install the bolts.

Install the new halfshaft nut.


Wheel Studs
Special Tool(s)
C-Frame and Screw

211-023 (T74P-3044-A1)

1 W707287 Wheel stud
Removal
sure correct retention of these parts.
2. NOTICE: Never use a hammer to remove a wheel stud. Damage to the wheel hub may result.
Place the wheel hub in a soft-jawed vise and, using the C-Frame and Screw, remove the wheel stud.
Installation
1. Position the new wheel stud in the wheel bearing and hub assembly, aligning the serrations in the
wheel hub flange made by the original wheel stud.
2. NOTICE: Do not use power tools to install the wheel stud. The serrations on the flange can be
stripped.
Wheel Studs 1785

NOTE: Do not use the wheel nut that came with the vehicle.
NOTE: Make sure to use washers that have an ID that is larger than the OD of the wheel stud
serrations. Use enough washers (approximately 4) to allow the wheel stud to fully seat against the hub
flange.
Install 4 washers and a wheel nut on the wheel stud and tighten the wheel nut until the stud seats
against the flange.
3. Remove the wheel nut and washers.

Discard the wheel nut.
Wheel Studs 1786


Upper Arm
Special Tool(s)

204-592

1 W712774 Upper arm-to-frame bolt
2 5A983 Camber set shim
3 W711495 Flagnut
4 5A814 Upper arm
5 W520215 Upper arm-to-wheel knuckle nut
Removal
2. Remove and discard the upper arm-to-wheel knuckle nut.
3. Using the Ball Joint Separator, separate the upper arm from the wheel knuckle.
Upper Arm 1787

4. Remove and discard the upper arm-to-frame bolt, washer, camber set shim and flagnut.
5. Remove the upper arm.
Installation
Install the upper arm and loosely install the new upper arm-to-frame bolt, washer, camber set shim
and flagnut.
Loosely install the new upper arm-to-wheel knuckle nut.
4. With the weight of the vehicle on the wheel and tires, tighten the upper arm-to-frame bolt to 225 Nm
(166 lb-ft).
5. With the weight of the vehicle on the wheel and tires, tighten the upper arm-to-wheel knuckle nut to
103 Nm (76 lb-ft).
6. Check and, if necessary, adjust the rear alignment. For additional information, refer to Section 204-00
.
Upper Arm 1788


Lower Arm
Special Tool(s)

204-592

2 5B530 Lower arm
3 W712104 Lower shock absorber bolt
4 W520217 Lower shock absorber nut
5 W711481 Lower arm-to-frame flagnut
6 W712774 Lower arm-to-frame bolt
Removal
NOTE: Orientation of the suspension fasteners is important. Make sure the fasteners are installed in the same
direction as they were in when removed.
2. If equipped, disconnect the air suspension height sensor connecting link from the lower arm.
3. Remove and discard the shock absorber lower bolt and flagnut.
4. Remove and discard the lower arm-to-frame bolt and flagnut.
Lower Arm 1789

6. NOTICE: Do not damage the ball joint boot while installing the Ball Joint Separator.
Using the Ball Joint Separator, separate the lower ball joint from the wheel knuckle.
7. Swing the lower arm to the rear of the vehicle and remove the lower arm.
Installation
1. Position the lower arm ball joint onto the wheel knuckle and install the new lower ball joint nut.
2. NOTE: Do not tighten the lower arm-to-frame bolt at this time.
Install the new lower arm-to-frame bolt and flagnut.
Snug the bolt to 50 Nm (37 lb-ft).
3. NOTE: Do not tighten the shock absorber lower nut at this time.
Position the lower arm and install a new shock absorber lower bolt and nut.
5. Lower the vehicle so that the weight of the vehicle is on the wheel and tire assemblies.
6. Tighten the lower arm-to-frame bolt to 225 Nm (166 lb-ft).
7. Tighten the shock absorber lower bolt to 550 Nm (406 lb-ft).
8. If equipped, connect the air suspension height sensor connecting link to the lower arm.
9. Check and, if necessary, align the rear end. For additional information, refer to Section 204-00 .
Lower Arm 1790

Lower Arm 1791


Trailing Arm - Upper

1 5B672 Upper trailing arm
2 W711865 Upper trailing arm-to-wheel knuckle bolt
3 W711480 Upper trailing arm-to-frame flagnut
4 W711478 Upper trailing arm-to-frame bolt
Removal
2. Remove and discard the upper trailing arm-to-wheel knuckle bolt.
3. Remove and discthe upper trailing arm-to-frame bolt and flagnut.
4. NOTE: After removal of the upper trailing arm, inspect the knuckle bushing for excessive wear or
damage and install new as necessary. For additional information, refer to Wheel Knuckle Bushing in
this section.
Remove the upper trailing arm.
Installation
1. NOTE: Do not tighten the bolt at this time.
Install the upper trailing arm and loosely install the new upper trailing arm-to-frame bolt and flagnut.
Loosely install the new upper trailing arm-to-wheel knuckle bolt.
Trailing Arm - Upper 1792

4. Lower the vehicle so that the weight of the vehicle is resting on the wheel and tires.
5. Tighten the upper trailing arm-to-frame bolt and flagnut to 275 Nm (203 lb-ft).
6. Tighten the upper trailing arm-to-wheel knuckle bolt to 250 Nm (184 lb-ft).
Trailing Arm - Upper 1793


Trailing Arm - Lower

1 W711170 Lower trailing arm-to-wheel knuckle bolts (2 required)
2 5B674 Lower trailing arm
3 W711478 Lower trailing arm-to-frame bolt
4 W711480 Lower trailing arm-to-frame flagnut
Removal
2. Remove and discard the 2 lower trailing arm-to-wheel knuckle bolts.
4. Remove the lower trailing arm.
Installation
Install the lower trailing arm and loosely install the new lower trailing arm-to-frame bolt and flagnut.
Loosely install the 2 new lower trailing arm-to-wheel knuckle bolts.
5. Tighten the 2 lower trailing arm-to-wheel knuckle bolts to 103 Nm (76 lb-ft).
Trailing Arm - Lower 1794

6. Tighten the lower trailing arm-to-frame bolt to 275 Nm (203 lb-ft).
Trailing Arm - Lower 1795


Toe Link

1 W711237 Toe link-to-wheel knuckle bolt
2 5A972 Toe link
3 W71339 Toe link-to-frame cam bolt
4 W713340 Cam washer
5 W707254 Toe link-to-frame nut
Removal
2. Index-mark the cam bolt and cam washer positions.
3. Remove and discard the toe link-to-wheel knuckle bolt and washer.
4. Remove and discard the toe link-to-frame cam bolt, cam washer and nut.
5. Remove the toe link.
Installation
1. Using the index marks made in removal Step 2, transfer the marks onto the new cam bolt and cam
washer.
Align the index marks and loosely install the new toe link-to-wheel knuckle bolt and washer.
Toe Link 1796

Loosely install the new toe link-to-frame cam bolt, cam washer and nut.
6. Tighten the toe link-to-wheel knuckle bolt to 225 Nm (166 lb-ft).
7. Align the index marks and tighten the toe link-to-frame cam nut to 275 Nm (203 lb-ft).
8. Check and, if necessary, adjust the rear toe. For additional information, refer to Section 204-00 .
Toe Link 1797



1 W520213 Stabilizer bar link nuts (4 required)
2 W520213 Stabilizer bar link lower nuts (4 required)
3 5K484 Stabilizer bar link (2 required)
4 5A772 Stabilizer bar
5 4A037 Stabilizer bar bushing (2 required)
6 5B491 Stabilizer bar bracket (2 required)
100-02 .
NOTE: The stabilizer bar links are designed with low friction ball joints that have a low breakaway
torque.
Remove the 4 stabilizer bar link nuts and the links.
Discard the nuts.

Remove the stone shields.
3. Remove the 4 stabilizer bar bracket nuts, the 2 stabilizer bar brackets and the stabilizer bar.
Discard the nuts.

4. NOTE: Inspect and, if necessary, install new stabilizer bar bushings.
NOTE: The rear stabilizer bar must be installed with the center hump facing downward.
NOTE: The rear stabilizer bar bushings must be installed outboard of the upset rings on the stabilizer
bar.
NOTE: The stabilizer bar link stone shields must be installed on the stabilizer bar attachment point.


Wheel Knuckle Bushing
Special Tool(s)
Bushing Remover
204-034
Bushing Remover
204-589/1
Bushing Remover/Installer
204-608
Forcing Screw, Bearings and Washers

205-813

2 5B672 Upper trailing arm
3 - Wheel knuckle bushing
4 5A970 LH/ 5A971 RH Wheel knuckle
Removal

Position the upper trailing arm upward to access the wheel knuckle bushing.
Wheel Knuckle Bushing 1800

3. Using the Bearings and Washers Forcing Screw, the Bushing Remover and the Bushing
Remover/Installer, remove the wheel knuckle bushing.
Installation
1. Clean and inspect the wheel knuckle bushing bore for damage or excessive wear.
2. Position the new wheel knuckle bushing with the larger void facing towardthe upper trailing arm.
3. Install the Bearings and Washers Forcing Screw, the Bushing Remover and the Bushing
Remover/Installer.
4. NOTE: Do not use the forward forcing screw nut to install the bushing. The forward forcing screw
nut is only used to correctly position and align the bushing for installation.
Hand tighten the forward forcing screw nut to align the bushing with the rearward side of the wheel
knuckle bore.
5. NOTICE: Use the rearward forcing screw nut to install the bushing or damage to the bushing
and/or the wheel knuckle bushing bore may result.
Tighten the rearward forcing screw nut and install the bushing until it is centered in the wheel
knuckle.

6. NOTE: After installing the wheel knuckle bushing, make sure to measure the bushing position in the
wheel knuckle bore. The measurement from the bushings outer metal surface to the machined face
surface of knuckle bore should be 2.54 mm (0.16 in) +/- 0.25 mm (0.01 in).
If necessary, use the Bearings and Washers Forcing Screw, the Bushing Remover and the Bushing
Remover/Installer to adjust the bushing position in the wheel knuckle bushing bore.
7. NOTE: Do not tighten the trailing arm-to-wheel knuckle bolt at this time.
Connect the upper trailing arm-to-the wheel knuckle and loosely install the bolt.
10. Tighten the new upper trailing arm-to-the wheel knuckle bolt to 250 Nm (184 lb-ft).


Wheel Knuckle
Special Tool(s)

204-592

3 W520213 Stabilizer bar link nut
5 W71170 Lower trailing arm-to-wheel knuckle bolt
7 5A970 LH/ 5A971 RH Wheel knuckle
8 2A635 RH/ 2A809 LH Parking brake cable
Removal
1. Remove the wheel bearing and wheel hub assembly. For additional information, refer to Wheel
Bearing and Wheel Hub in this section.
Wheel Knuckle 1803

2. Remove the parking brake shoes. For additional information, refer to Section 206-05 .
3. Remove the brake disc shield.
4. Compress the spring and depress the retaining tabs and detach the parking brake cable from the wheel
knuckle and parking brake lever.
8. Using the Ball Joint Separator, separate the lower ball joint from the wheel knuckle.
9. Remove and discard the 2 bolts and disconnect the lower trailing arm from the wheel knuckle.
10. Remove and discard the bolt and disconnect the toe link from the wheel knuckle.
Using the hex-holding feature, remove and discard the stabilizer bar link nut and disconnect the link
from the wheel knuckle.
12. Remove the upper trailing arm-to-wheel knuckle bolt and the wheel knuckle.
Discard the bolt.
Installation
1. NOTE: Do not tighten the upper trailing arm-to wheel knuckle bolt at this time.
Position the wheel knuckle and loosely install the new upper trailing arm-to-wheel knuckle bolt.
2. Connect the stabilizer bar link to the wheel knuckle and install the new nut.
3. NOTE: Do not tighten the toe link-to-wheel knuckle bolt at this time.
Connect the toe link-to-the wheel knuckle and loosely install the new bolt.
Wheel Knuckle 1804

4. Connect the lower trailing arm to the wheel knuckle and install the 2 new bolts.
5. Position the lower ball joint onto the wheel knuckle and install the new lower ball joint nut.
6. Position the upper arm and install the new upper arm-to-wheel knuckle nut.
Tighten the nut to 103 Nm (76 lb-ft).
7. Compress the spring, insert the retaining tabs and attach the parking brake cable to the wheel knuckle
and parking brake cable lever.
8. Install the brake disc shield.
9. Install the parking brake shoes. For additional information, refer to Section 206-05 .
10. Install the wheel bearing and wheel hub assembly. For additional information, refer to Wheel Bearing
and Wheel Hub in this section.
12. Tighten the toe link-to-the wheel knuckle bolt to 225 Nm (166 lb-ft).
13. Tighten the upper trailing arm-to-wheel knuckle bolt to 250 Nm (184 lb-ft).
Wheel Knuckle 1805


Part
1 - Shock absorber upper mount nut (3 required) (part of
18080 kit)
2 - Shock rod nut (part of 18080 kit)
4 5536 Insulator
5 18A047 Dust boot
6 - Jounce bumper (part of 18080 kit)
7 5534 Spring
1. Remove the lower arm. For additional information, refer to Lower Arm in this section.
2. Remove and discard the shock absorber upper mount nuts.

3. Remove the shock absorber and spring assembly.
4. NOTE: If the individual spring and/or shock components are not being serviced, continue with Step
7.
NOTE: For reference during assembly, index-mark the uppet, spring and shock absorber.
absorber.

5. While holding the shock rod, remove the nut and washer.
Remove the shock absorber.
Discard the nut.
6. Remove the upper mount, dust boot and insulator.


Ball Joint - Lower
Special Tool(s)

204-358

205-086

1 3050 Ball joint
2 5B530 Lower arm
3 W302856 Ball joint snap ring
Removal
same part numbers or equivalent , if replacement is necessary. Do not use a replacement part of lesser
quality or substitute design. Torque values must be used as specified during reassembly to make sure
correct retention of these parts.
2. Remove and discard the ball joint snap ring.

3. Using the C-Frame and Screw Installer/Remover and the Ball Joint Installer/Remover, remove the
ball joint.
Installation
1. NOTICE: Do not damage the ball joint boot when installing the special tool.
NOTE: Clean and inspect the ball joint bore for bore damage before installing a new ball joint.
Using the C-Frame and Screw Installer/Remover and the Ball Joint Installer/Remover, install the ball
joint.
2. NOTE: Always use a new ball joint snap ring.
Install a new snap ring.

SECTION 204-04: Wheels and Tires 2011 Expedition, Navigator Workshop Manual
Material

Capacity
High Temperature Nickel Anti-Seize - -
Lubricant
XL-2
Motorcraft Wheel and Tire - -
Cleaner
ZC-37-A
Item Specification
Tire Inflation
Tires See Safety Certification Label on driver door jamb
Wheel Weights
Wheel weight Use a wheel weight manufacturer's rim gauge to determine the correct wheel weight
type application
Valve stem-to-Tire Pressure Monitoring System (TPMS) sensor screw 1.5 13
Wheel nuts a - -


Wheels And Tires
Safety Precautions
WARNING: Vehicle may have multiple drive wheels. Do not use engine to power the driveline
unless all drive wheels are elevated off the ground. Drive wheels in contact with ground could cause
unexpected vehicle movement. Failure to follow this instruction may result in serious personal injury.
WARNING: Always match the tire size to the wheel size during assembly. Incorrect matching can
result in tire bead damage or tire separation from the wheel. Failure to follow this instruction may
result in serious personal injury to technician or vehicle occupant(s).
WARNING: Before servicing any tire, ask the customer if anyone injected a tire sealant into the tire.
Tire sealants may be flammable and can burn or explode if exposed to an ignition source. Failure to
follow this instruction may result in serious personal injury.
WARNING: Replacement wheels must be equivalent to the original equipment wheels in:
load carrying capacity.

diameter, width and offset.
pilot hole and bolt circle.
Combined load carrying capacity of replacement wheels for a given axle, must be equal to or greater than that
axle's gross axle weight rating (GAWR) identified on the vehicle's Safety Compliance Certification label. All
other specifications should be evaluated by measurement of both the original wheel and the replacement
wheel. If specifications are not equivalent, the safety and handling of the vehicle may be degraded, which may
result in serious injury to the vehicle occupant(s).
WARNING: Keep eyes away from valve stem when deflating tires. Reduce air pressure in tire as
much as possible by pushing in valve core plunger prior to removing the core. Escaping air can carry
particles that can injure the eyes. Failure to follow these instructions may result in serious personal
injury.
WARNING: Only use replacement tires that are the same size, load index, speed rating and type
(such as P-metric versus LT-metric or all-season versus all-terrain) as those originally provided by
Ford. The recommended tire and wheel size may be found on either the Safety Compliance
Certification Label or the Tire Label, which is located on the B-pillar or edge of the driver's door. If the
information is not found on these labels, consult a Ford dealer. Use of any tire or wheel not
recommended by Ford can affect the safety and performance of the vehicle, which could result in an
increased risk of loss of vehicle control, vehicle rollover, personal injury and death. Additionally, the
use of non-recommended tires and wheels could cause steering, suspension, axle or transfer case/power
transfer unit failure.
NOTICE: Do not clean aluminum wheels with steel wool, abrasive-type cleaners or strong detergents or
damage to the wheel finish may occur. Use Wheel and Tire Cleaner ZC-37-A or -B or equivalent.
Wheels And Tires 1812

Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including
full-rated load capacity when inflated to recommended inflation pressures.
Correct tire pressure and driving techniques have an important influence on tire life. Heavy cornering,
excessively rapid acceleration and unnecessary sharp braking increase tire wear.
To equalize tire wear, the tires should be rotated at recommended intervals.
Tire Pressure Monitoring System (TPMS)
NOTE: The Smart Junction Box (SJB) is also identified as the Generic Electronic Module (GEM).
The Tire Pressure Monitoring System (TPMS) includes:
the SJB , TPMS functionality is integrated within the SJB .

four valve stem mounted tire pressure sensors.
an Instrument Cluster (IC) indicator.
a message center (if equipped).
Tire Pressure Monitoring System (TPMS) Module
The SJB contains the TPMS functionality. Refer to Tire Pressure Monitoring System (TPMS) in Diagnosis
and Testing for TPMS fault diagnosis and repair.
The SJB compares the information of each tire pressure sensor transmission against a pressure limit. If the
SJB determines that the tire pressure has fallen below the low limit, the SJB communicates this to the IC on
the vehicle communication bus.
Tire Pressure Monitoring System (TPMS) Pressure Sensor
The SJB monitors the air pressure in the 4 road tires with tire pressure sensors. The sensors transmit radio
frequency signals to the SJB approximately every 60 seconds when the vehicle speed exceeds 32 km/h (20
mph).
The tire pressure sensors are battery operated and are mounted to the valve stem.
Instrument Cluster (IC) and Message Center
The IC illuminates the TPMS indicator when it receives a message from the TPMS to do so and displays the
appropriate message(s) in the message center (if equipped).
The IC and message center are diagnosed and serviced in their own respective workshop manual sections.


Wheels And Tires
Special Tool(s)
Digital Tire Pressure Gauge

204-354
Hunter Road Force Wheel Balancer

GSP9700 Series
WARNING: Vehicle may have multiple drive wheels. Do not use engine to power the driveline
unless all drive wheels are elevated off the ground. Drive wheels in contact with ground could cause
unexpected vehicle movement. Failur to follow this instruction may result in serious personal injury.
Verify the customer concern by carrying out a road test on a smooth road. If any vibrations are apparent, GO
to Symptom Chart - NVH .
To maximize tire performance, inspect for signs of incorrect inflation and uneven wear, which may indicate a
need for balancing, rotation or front suspension alignment.
Correct tire pressure and driving techniques have an important influence on tire life. Heavy cornering,
excessively rapid acceleration and unnecessary sharp braking increase tire wear.
Replacement tires must follow the recommended:
tire sizes.
speed rating.
load range.
tire construction type.
The use of any other tire/wheel size, load range or type can seriously affect:
ride.
handling.
speedometer/odometer calibration.
vehicle ground clearance.
tire clearance between the body and chassis.
wheel bearing life.
braking performance.
New wheels need to be installed when the vehicle wheels:
are bent.
are cracked.
are dented.
are heavily corroded.

are leaking.
have elongated wheel hub bolt holes.
have excessive lateral or radial runout.
It is mandatory to use only the tire sizes recommended on the tire label located on the driver door or door
pillar attached to the vehicle. Larger or smaller tires can damage the vehicle, affect durability and require
changing the speedometer calibration. Make sure wheel size and offsets match those recommended for the tire
in use.
1. Inspect the tires for signs of uneven wear. Refer to the following descriptions to identify the type of
wear and GO to Symptom Chart - Tire Wear for the appropriate repair action to be carried out.
2. Check the tires for:

cuts.
stone bruises.
abrasions.
blisters.
embedded objects.
3. Check the valve stems for:

cracks.
cuts.
Install a new valve stem when damage is found or anytime a new tire is installed.
4. Tread wear indicators are molded into the bottom of the tread grooves. Install a new tire when the
indicator bands become less than 2/32 inch.
Tire Wear
Tire wear is commonly defined as a loss of tread depth. Tire tread wear occurs due to friction with the contact
surface (road/pavement). The tread should wear down uniformly all the way around the circumference of the
tire and all the way across the tread face. When this does not occur, the tire may have abnormal/incorrect
wear.
Normal Tire Wear
Normal tire wear is identified as even wear around and across the tread. Because there are many factors
(driving style, road surfaces, type of vehicle, type of tire) that can affect tire wear, there is no absolute mileage
expectation for a normal wear condition. A tire is considered worn-out when the tread has worn to the level of
the tread-wear indicators.
Abnormal/Incorrect Tire Wear
Abnormal/incorrect tire wear is identified as tire wear that is not even around or across the tread and that
creates performance-related issues.
Abnormal/incorrect wear can be caused by numerous factors, some of which include driving style (aggressive,
passive), climate (hot, cold), road conditions, vehicle loading and maintenance (correct tire pressure, rotation
intervals and balance). It is important to determine the root cause of wear on a vehicle before carrying out
repair. Tires exhibiting abnormal/incorrect tire wear may still be serviceable provided that the minimum tread
depth is greater than 2/32 inch and the tire is not causing a vehicle performance (noise/vibration) concern.
Normal Tire Wear 1816

Some abnormal/incorrect wear patterns look the same all the way around the tread of the tire, other wear
patterns are not consistent and can occur in various spots on the tread area. The underlying causes of the 6
wear categories are different. Refer to the following descriptions to identify the type of wear and GO to
Symptom Chart - Tire Wear for the appropriate repair action to be carried out.
Inner Edge/Shoulder Wear
Inner edge (or shoulder) wear occurs on the inside edge of the tire and is usually caused by excessive toe out
and/or excessive negative camber. If the tread depth of the outer shoulder is at least 50% greater than the tread
depth of the inner shoulder, the tire is experiencing inner edge/shoulder wear. To determine whether tires have
this type of wear, visually inspect the tires. In some instances, it may be necessary to measure the tread depth
of each rib and compare it to that of the shoulder.
NOTE: RF tire shown, others similar.
Outer Edge/Shoulder Wear
Outer edge (or shoulder) wear occurs on the outside edge of the tire and is usually caused by excessive toe in
and/or excessive positive camber. If the tread depth of the inner shoulder is at least 50% greater than the tread
depth of the outer shoulder, the tire is experiencing outer edge/shoulder wear. To determine whether tires have
this type of wear, visually inspect the tires. In some instances, it may be necessary to measure the tread depth
of each rib and compare it to that of the shoulder.
NOTE: RF tire shown, others similar.
Heel/Toe Wear
Heel/toe wear (also known as feathering) occurs along the outside or inside edge/shoulder of the tire. To
determine whether tires have this type of wear, visually inspect the tires in both the inside and outside
shoulder ribs. In some instances, it may be necessary to measure the difference in tread depth of leading
versus trailing edge of each lug in the inside and outside shoulder rib.
Abnormal/Incorrect Tire Wear 1817

Diagonal Wear
Diagonal wear occurs diagonally across the tread area and around the circumference of the tire. To determine
whether tires have this type of wear, visually inspect the tires to determine if the wear pattern runs diagonally
across the tread and around the circumference of the tire. In some instances, the difference in tread depth
along the diagonal wear pattern may need to be measured.
Symptom Chart - Tire Wear
Symptom Chart - Tire Wear

NOTE: For suspension system and additional alignment diagnosis, refer to Section 204-00 .
Inner edge/shoulder wear
Excessive toe out and/or negative camber
Incorrect wheel and tire assembly rotation intervals
High-speed cornering
Outer edge/shoulder wear
Excessive toe in and/or positive camber
High-speed cornering
Heel/toe wear
Diagonal Wear 1818

Excessive toe in/out

ROTATE the wheel and tire assemblies. CHECK the alignment, ADJUST as necessary.
Diagonal wear
Incorrect tire rotation intervals
Loose, worn or damaged suspension components
Symptom Chart - NVH
Symptom Chart - NVH

tools, an explanation of their uses and a glry of common terms, refer to Section 100-04 . Since it is possible
any one of multiple systems may be the cause of a symptom, it may be necessary to use a process of
Wobble or shimmy
Bent wheel
INSTALL a new wheel as necessary.
Damaged tire
INSTALL a new tire as necessary.
Loose wheel nuts
TIGHTEN to specification.
High-speed shake
Tires/wheels
REFER to Wheel and Tire Runout Component Tests in this section.
Vehicle vibration
Diagonal Wear 1819

Tires/wheels
REFER to Wheel and Tire Runout Component Tests in this section.
Pinpoint Tests
For a description of the various tire wear patterns, refer to Inspection and Verification.
Pinpoint Test A: Inner Edge/Shoulder Wear

Excessive toe out
Incorrect wheel and tire rotation
PINPOINT TEST A: INNER EDGE/SHOULDER WEAR

A1 MEASURE THE TREAD
DEPTH
Yes
Using a tread depth gauge or ROTATE the wheel and tire assemblies.
similar tool, measure the inside
edge/shoulder tread depth. CHECK and ADJUST the toe to nominal +0.15 degrees (toe
Is the tread depth greater than in). CHECK and ADJUST caster and camber to nominal.
2/32 inch? REFER to Section 204-00 .
No
INSTALL a new tire(s). CHECK and ADJUST the toe to
nominal. CHECK and ADJUST caster and camber to nominal.
Pinpoint Test B: Outer Edge/Shoulder Wear

Excessive toe in
PINPOINT TEST B: OUTER EDGE/SHOULDER WEAR

B1 MEASURE THE TREAD DEPTH
Yes
Using a tread depth gauge or ROTATE the wheel and tire assemblies.
similar tool, measure the outside
edge/shoulder tread depth. CHECK and ADJUST the toe to nominal -0.15 degrees (toe
PINPOINT TEST A: INNER EDGE/SHOULDER WEAR 1820

Is the tread depth greater than out). CHECK and ADJUST caster and camber to nominal.
2/32 inch? REFER to Section 204-00 .
No
INSTALL a new tire(s). CHECK and ADJUST the toe to
nominal. CHECK and ADJUST caster and camber to
nominal. REFER to Section 204-00 .
Pinpoint Test C: Diagonal Wear

Incorrect tire inflation
Loose, worn or damaged suspension components
PINPOINT TEST C: DIAGONAL WEAR

C1 MEASURE THE
TREAD DEPTH
Yes
Using a tread If no performance concerns (noise/vibration) are present, the tire can remain
depth gauge or in service. CHECK the air pressure in the tires, ADJUST as necessary.
similar tool, ROTATE the wheel and tire assemblies. INSPECT for loose, worn or
measure the tread damaged suspension components. INSTALL new components as necessary.
depth of the wear CHECK the alignment and ADJUST as necessary. REFER to Section 204-00 .
pattern.
Is the tread No
depth greater INSTALL a new tire(s). CHECK the air pressure in the tires, ADJUST as
than 2/32 inch? necessary. ROTATE the wheel and tire assemblies. INSPECT for loose, worn
or damaged suspension components. INSTALL new components as
necessary. CHECK the alignment and ADJUST as necessary. REFER to
Section 204-00 .
Component Tests
Radial Runout
Radial runout is the egg-shaped deviation from a perfect circle and is measured perpendicular to the
circumference. On a wheel and tire assembly, this means measuring the center tire tread rib. The center rib is
indicative of the condition of the tire as a whole. Total runout is the difference between the
maximum-to-minimum gauge reading. The high spot is the location of maximum runout.
PINPOINT TEST B: OUTER EDGE/SHOULDER WEAR 1821

Item Description
1 High spot
2 Low spot
Loaded Runout Measurement (Hunter Road Force 9700 Series Wheel Balancer)
NOTE: Diagnosis of tire/wheel vibration should not be performed on tires with less than 320 km (200 mi).
Some initial tire/wheel vibration issues (such as flat spotting) will correct themselves after the tires have been
in service for 320 km (200 mi).
This procedure is intended to assist with the diagnosis of wheel and tire assembly runout and/or force
variation issues.
The Hunter Road Force 9700 Series Wheel Balancer measures the wheel and tire assembly's loaded runt and
the tire's radial spring rate. The balancer then converts the runout into pounds of force (termed as Road
Force). Measuring loaded runout (Road Force) is more effective than measuring unloaded runout using a
dial indicator.
1. Using a tire crayon, record the vehicle position on the inward sidewall of all 4 tires.
2. Remove the wheel and tire assemblies. For additional information, refer to Wheel and Tire in this
section.
3. NOTE: Use only the Digital Tire Pressure Gauge any time tire pressures are measured to be sure that
accurate values are obtained.
Make sure that the tire pressures are set to the correct pressure as indicated on the Vehicle
Certification (VC) label.
4. NOTICE: Make sure that the correct wheel balancer adapters are used when mounting the
assembly to the wheel balancer or damage to the wheel may occur.
NOTE: Make sure that the wheel and tire assembly is clean and free of foreign material prior to
installation on the balancer.
NOTE: The wheel balancer inflation station must be turned OFF for tires with inflation pressures of
414 kPa (60 psi) or above.
Mount the wheel and tire assembly on a suitable wheel balancer using the correct wheel balancer
adapters as shown. Rer to the list of recommended wheel balancer adapters on the PTS website.
PINPOINT TEST C: DIAGONAL WEAR 1822

Item Description
1 Wheel balancer
2 Cone
3 Wheel and tire assembly
4 Finger plate
5 Balancer wing nut
5. Measure the Road Force.

Temporarily mark the high spot and the Road Force value on the sidewall of the tire. If the
wheel and tire assembly Road Force value is greater than 11 kg (25 lb), carry out the Match
Mounting procedure to optimize the wheel and tire assembly.
If the wheel and tire assembly Road Force value is 11 kg (25 lb) or less, permanently mark
the high spot and the Road Force value on the inward sidewall of the tire for reference
during future wheel and tire service. Balance the assembly and install the wheel and tire on
the vehicle using the Wheel-to-Hub Optimization procedure.
Runout Measurement (Dial Indicator)
NOTE: Diagnosis of tire/wheel vibration should not be performed on tires with less than 320 km (200 mi).
Some initial tirel vibration issues (such as flat spotting) will correct themselves after the tires have been in
service for 320 km (200 mi).
NOTE: Loaded run-out measurements are the preferred method for verifying tire serviceability. While a dial
indicator can be used to optimize the position of the tire on the wheel the unloaded run-out measurement
cannot accurately determine if the tire should be removed from service.
The following procedures should be used if normal diagnostics leads to a potential runout issue.
Some vehicles may exhibit a wheel and tire vibration caused by excessive runout. Radial runout
measurements can be taken using a dial indicator and should be measured with the wheel and tire assembly
mounted on a suitable wheel balancer. The dial indicator should be mounted securely to eliminate gauge
movement when measuring runout.
1. NOTE: Use only the Digital Tire Pressure Gauge any time tire pressures are measured to be sure that
accurate values are obtained.
Make sure that the tire pressures are set to the correct pressure as indicated on the VC label.
2. Using a tire crayon, record the vehicle position on the inward sidewall of all 4 tires.
3. Remove the wheel and tire assemblies. Refer to Wheel and Tire in this section.

4. NOTICE: Make sure that the correct wheel balancer adapters are used when mounting the
assembly to the wheel balancer or damage to the wheel may occur.
NOTE: Make sure that the wheel and tire assembly is clean and free of foreign material prior to
installation on the balancer.
Mount the wheel and tire assembly on a suitable wheel balancer using the correct wheel balancer
adapters as shown. Refer to the list of recommended wheel balancer adapters on the PTS website.
Item Description
1 Wheel balancer
2 Cone
3 Wheel and tire assembly
4 Finger plate
5 Balancer wing nut
5. NOTE: Masking tape can be applied on the center tread rib to allow for a smoother measuring
surface. Some fluctuation of the gauge reading is expected. Observe the overall sweep of the gauge
from the highest to the lowest spot on the tire.
Position the dial indicator and stand with the dial indicator on the center tread rib.
Rotate the wheel and tire assembly (or wheel) to locate the low spot.
Adjust the runout gauge to read 0.
Rotate the wheel and tire assembly one complete revolution to make sure that the low spot
has been found and that the dial indicator returns to a 0 reading.
6. While slowly and constantly rotating the wheel and tire assembly (or wheel), measure the radial
runout.

Note the variance (runout) from 0 on the dial of the gauge.
If the runout reading of a wheel and tire assembly is greater than 1.14 mm (0.045 in), locate
and temporarily mark the high spot and runout reading on the sidewall of the tire and carry
out the Match Mounting procedure to optimize the wheel and tire assembly.
If the runout reading of a wheel and tire assembly is 1.14 mm (0.045 in) or less, permanently
mark the high spot and the runout reading on the inward sidewall of the tire for reference
during future wheel and tire service. Balance the assembly and install the wheel and tire on
the vehicle using the Wheel-to-Hub Optimization procedure.
Match Mounting
NOTE: Road Force values in illustrations are shown in pounds.
Match mounting is a technique used to reduce radial runout or road force on wheel and tire assemblies.
Excessive runout is a source of ride quality complaints and match mounting can be used to minimize the
runout. Match mounting can be accomplished by changing the position of the tire on the wheel.
1. Position the wheel and tire assembly on a tire machine and put a reference mark on the tire sidewall at
the valve stem position.
Item Description
1 Valve stem
2 Reference mark
2. NOTICE: For tires equipped with a Tire Pressure Monitoring System (TPMS), the sensor,
cradle and strap may be damaged by incorrect tire mounting or dismounting. Dismount the tire
from the wheel as instructed in the Disassembly and Assembly procedure. Failure to follow
these instructions may result in TPMS component damage.
NOTE: Always make sure that the final high spot and measurement values are permanently marked
on the inward sidewall of the tire for reference during future wheel and tire service.
Using a suitable tire machine, separate the tire beads from the wheel.
Lubricate the tire beads using a suitable fast drying, corrosion inhibiting tire bead lubricant.

Position the tire 180 degrees (half-way around) on the rim so the valve stem reference mark is
now opposite the valve stem.
3. Re-inflate the wheel and tire assembly to the specified air pressure and measure the assembly again
using the dial indicator or Hunter Road Force 9700 Series Wheel Balancer. Mark the second high
spot on the tire.
If the runout or Road Force is reduced to within specifications, the concern has been
resolved. Balance the assembly and install on the vehicle using the Wheel-to-Hub
Optimization procedure.
4. If the second runout or Road Force measurement is still not within specification and both high spots
are close to each other (within 101.6 mm [4 in]), the root cause is probably the tire (the high spot
followed the tire).
To be SURE that the tire is causing the high runout, it is necessary to have 2 runout or Road
Force measurements that are not within specification and the high spots must be in
approximately the same location on the tire's sidewall. If the tire is the cause, install a new
tire, balance the assembly and install on the vehicle using the Wheel-to-Hub Optimization
procedure.
If the second high spot is not within 101.6 mm (4 in) of the first high spot, proceed to the next
step.
Item Descript
1 First high spot on the tire
2 Second high spot on the tire
5. If the second high spot is still above specification and is within 101.6 mm (4 in) of being opposite the
first high spot on the wheel, the root cause is probably the wheel (the high spot followed the wheel).
Dismount the tire from the wheel, mount the wheel on a balancer and check the wheel runout. If the
wheel runout exceeds 1.14 mm (0.045 in), install a new wheel, balance the assembly and install on the
vehicle using the Wheel-to-Hub Optimization procedure.
Item Description

6. NOTE: If the second high spot did not follow the wheel or the tire and the runout is still not within
specification, improvements may be made by rotating the tire 90 degrees (one-fourth turn).
Draw an arrow on the tire sidewall from the second high spot towards the first high spot (in the
shortest direction).
Separate the tire beads from the wheel and rotate the tire 90 degrees (one-fourth turn) in the
direction of the arrow.
Item Description
Wheel-to-Hub Optimization
Wheel-to-hub optimization is important. Clearance between the wheel and hub can be used to offset or
neutralize the Road Force or run-out of the wheel and tire assembly. For every 0.001 in of wheel-to-hub
clearance, the Road Force can be affected between 1 and 3 pounds depending on the tire stiffness.
NOTE: The example below illustrates how the clearance between the wheel and the hub can be used to offset
the high spot of radial run-out or Road Force. Following the procedure will ensure the best optimization.
1. Position the wheel and tire assembly on the vehicle so that the high spot location is at the 6 o'clock
position and install the wheel nuts by hand until snug.
2. NOTE: Do not allow the full weight of the vehicle to rest on the tires while tightening the wheel nuts.
Lower the vehicle until the tires make contact with the grou slightly loading the suspension. Tighten
the wheel nuts as described in Wheel and Tire in this section.


Tire Pressure Monitoring System (TPMS)
Special Tool(s)
Activation Tool, Tire Pressure Monitor

204-363

204-354

NOTE: The Smart Junction Box (SJB) is also referred to as the Generic Electronic Module (GEM).
The Tire Pressure Monitoring System (TPMS) monitors the air pressure of all 4 road tires. The
wheel-mounted tire pressure sensors transmit via radio frequency signals, to the SJB . TPMS functionality is
integral to the SJB . These transmissions are sent approximately every 60 seconds when the vehicle speed
exceeds 32 km/h (20 mph). The TPMS function compares each tire pressure sensor transmission against a
low-pressure limit. If it has been determined that the tire pressure has fallen below this limit, the SJB
communicates this on the vehicle communication bus to the Instrument Cluster (IC). The IC then illuminates
the TPMS indicator and displays the appropriate message(s) in the message center (if equipped).
For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire
pressures must be adjusted and the tire pressure sensors must be trained following a tire rotation. Failure to
train the sensors will cause the TPMS indicator to illuminate.
For vehicles with the same tire pressures for front and rear tires, tire rotation will not affect the system.
Ambient Temperature Change and Tire Pressure
WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous
chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush
immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of
the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the
correct procedures for hazardous material disposal. Failure to follow these instructions may result in
NOTICE: Do not inflate tire higher than maximum pressure stamped on tire sidewall. Premature tire
wear or damage to the tire may result.
Tire pressures fluctuate with temperature changes. For this reason, tire pressure must be set to specification
when tires are at outdoor ambient temperatures. If the vehicle is allowed to warm up to shop temperatures, and
Tire Pressure Monitoring System (TPMS) 1829

the outside temperature is less than shop temperature, the tire inflation pressure must be adjusted accordingly.
If the tires are inflated to specification at shop temperatures, and the vehicle is moved outdoors when the
outdoor ambient temperature is significantly lower, the tire pressure may drop enough to be detected by the
TPMS and activate the TPMS warning lamp.
As the ambient temperature decreases by 6C (10F), tire pressure decreases 7 kPa (1 psi). Adjust the tire
pressure by 7 kPa (1 psi) for each 6C (10F) ambient temperature drop as necessary to keep the tire at the
specified Vehicle Certification (VC) label pressure. Refer to the following tables to adjust the tire pressure
indoors for colder outside temperatures.
Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages
The TPMS indicator and vehicle message center (if equipped) sometimes displays faults that cannot be
resolved by the customer. Treat these messages as TPMS faults that must be serviced.
Tire Pressure Monitoring System (TPMS) Indicator Illuminates Continuously
NOTE: If the spare tire is in use, the damaged road tire must be repaired and installed on the vehicle to
restore complete TPMS functionality before carrying out any diagnosis.
NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain F-Series), the
tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will result in a false
low tire pressure event, which will cause the TPMS indicator to illuminate.
1. The TPMS indicator remains on continuously for the following condition:

Low Tire Pressure - The TPMS indicator is illuminated solid and the message center displays
LOW TIRE PRESSURE (if equipped). This is displayed when any of the tire pressures are
low. When this condition exists, the tire pressure must be adjusted to the recommended cold
pressure as indicated on the VC label.

2. NOTE: The TPMS sensors do not transmit when the vehicle is stationary. If the vehicle has been
stationary for more than 30 minutes, it will be necessary to wake up the sensors so they will transmit
the latest tire pressure information to the SJB .
If the vehicle has been stationary for more than 30 minutes, carry out the Tire Pressure Monitoring
System (TPMS) Sensor Activation procedure in this section.
Tire Pressure Monitoring System (TPMS) Indicator Flashes
The TPMS indicator flashes for 70 seconds, then remains ON solid when the ignition swch is turned to the
ON position, for the following conditions:
1. Tire Pressure Sensor Fault - If equipped, the message center will display TIRE PRESSURE SENSOR
FAULT when a tire pressure sensor is malfunctioning. GO to Symptom Chart .
2. No communication with the SJB ( TPMS is integral to the SJB ) - The TPMS indicator is illuminated
when the IC has not received any signals from the SJB for more than 5 seconds. If equipped, the
message center displays TIRE PRESSURE MONITOR FAULT. GO to Som Chart .
3. Tire Pressure Monitor Fault - If equipped, the message center will display TIRE PRESSURE
MONITOR FAULT when the TPMS is malfunctioning or communication with the IC has been lost.
GO to Symptom Chart .
Tire Pressure Monitoring System (TPMS) PID Definitions and Intermittent Troubleshooting
TPMS Status PID
The SJB monitors the TPMS status. The current status can be viewed by accessing the TPMS status PID:
TP_STAT using the scan tool. This helps identify the current system status and may aid in diagnosing the
system. The PID has 4 valid states:
1. TP_STAT = SENSOR FAULT.

If the module has not received the tire pressure status from 1 3 TPMS sensors for 20 minutes
when the vehicle speed is above 32 km/h (20 mph), the PID displays SENSOR FAULT.
2. TP_STAT = SYSTEM FAULT.

If the module has not received the tire pressure status from all 4 TPMS sensors for 20 minutes
and the vehicle speed is above 32 km/h (20 mph), the PID displays SYSTEM FAULT.
3. TP_STAT = LOW.
If the module has detected that at least 1 TPMS sensor is reporting low tire pressure, the PID
displays LOW.
4. TP_STAT = SYSTEM ACTIVE.

If the TPMS is functioning normally, the PID displays SYSTEM ACTIVE.
TPMS Last Warning Event PID Definitions
The TPMS uses the TPMS last warning event PIDs to store detailed information about the last 5 times the
TPMS warning indicator was activated. These PIDs can be used to acquire more information about a
particular TPMS event.

EVT1_IGN through EVT5_IGN
The number of key cycles since the TPMS warning indicator was activated. This PID cycles from zero to 255
and then starts over from zero again. This can be used to determine how long ago a TPMS event occurred and
the time (in key cycles) between events.
EVT1_TLOC through EVT5_TLOC
This is the last programmed location for the sensor identifier causing each TPMS event. Due to tire rotation,
the sensor may no longer be at the original location. It is suggested that all the PIDs be recorded, the system
retrained, and then the sensor identifier PIDs be used to pinpoint the actual location of each sensor.
EVT1_PSI through EVT5_PSI
This is the tire pressure associated with each TPMS warning indicator event. This can be used along with the
function code to clearly identify the TPMS events that were strictly due to low pressure. It can also be used to
determine when a sensor is transmitting inaccurate tire pressure.
EVT1_STAT through EVT5_STAT
Describes the warning status of each TPMS event by using the information received from the TPMS status
(TP_STAT) PID. If there is a communication issue, the status could be Normal.
Unknown
Normal (normal operation)
Low (low pressure event)
Fault (sensor fault or system fault)
EVT1_TxID through EVT5_TxID
This is the identifier of the sensor involved in each TPMS event. EVT1 is the most recent event that triggered
the TPMS warning indicator.
Wheel Rotation and Sensor Training Techniques
Moving a Problem Sensor/Wheel to a Different Position
If a sensor in a certain location has caused several events, yet the sensor trains and seems to operate normally,
moving that particular wheel to a different location on the vehicle is a good way to isolate the issue to a
certain sensor/wheel location. Rotate the wheels and road test the vehicle. This can be done in an attempt to
replicate the issue. This determines if the issue followed the sensor or remained in the original sensor location.
Training Sensors in a Different Order
This is a technique to get past a left front sensor that may not be responding to determine if the remaining
sensors train to the module. This can help save time determining if other sensors are having issues or if the
module is experiencing training difficulties with a certain location.
Training Known Good Sensors From Another Vehicle
Training known good sensors from another vehicle cannot differentiate between a faulted module and Radio
Frequency Interference (RFI), as some noise source could be preventing the module from receiving the tire
pressure status from the original sensors as well as the known good sensors. This technique that can be used to
differentiate between a sensor and module issue. If the module in the vehicle cannot train any of its own
sensors, and likewise cannot train known good sensors from another vehicle, then the issue is with the module
or the RFI , and not with the original sensors. The original sensors should not be replaced.
EVT1_IGN through EVT5_IGN 1832

Items That Cause RFI
Non-OEM Equipment
The following equipment has been found to sometimes cause RFI :
Video equipment has been found to cause RFI especially when the video and power supply lines are
near the TPMS .
Car alarms (even those installed by dealerships) have been found to create enough RFI to cause the
TPMS to malfunction or lose considerable range. These car alarms can sometimes be difficult to
locate, as they are usually hidden somewhere out of the way for reduced accessibility.
Many different in-vehicle cell phone chargers have been found to cause considerable RFI . The
vehicles with the power point closest to the TPM are the most affected. It must be noted that most cell
phone chargers do not produce high levels of RFI all the time. This depends on the state of charge of
the cell phone battery. The phone must be almost completely discharged in some cases.
Power supplies and DC/AC inverters typically create a lot of RFI . Most consumer grade equipment
has very little filtering or shielding.
OEM Modules
In some cases, the RFI may actually be caused by a module or ground on the vehicle. Depending on the
severity of the issue, a dirty ground, improperly built ground shield or module can disable the system.
Modules that have microcontrollers using clock circuits to create the timing pulses for the microprocessor
may radiate RFI .
Using Customer's Electronics to Pinpoint the Radio Frequency Interference (RFI) Source
This can be a way to determine the cause of an issue well before the sensors and module are replaced with
little or no affect on the system performance. Since this takes more up-front work, it relies on working with
the customer to determine what equipment was being used at the time of the event.
Options for Eliminating Intermittent TPMS Conditions Caused by RFI
If an OEM component or customer device is causing an RFI issue, replace the device.
If a phone charger is causing an RFI issue, the customer should consult their cell phone provider to
acquire a different phone charger.
If a device such as a dealer-installed alarm is causing an RFI issue, move the device to another
location on the vehicle. In the case of a portable device, move the power cord to another power point
location.
In summary, if the RFI source is present and cannot be moved or replaced, the intermittent issue remains. The
vehicle owner must accept RFI and the unwanted system operation it can cause.
1. NOTE: The tire pressure sensors are not designed to be used with aftermarket wheels.
NOTE: The use of run-flat tires (tires with steel body cord plies in the tire sidewall) where not
originally equipped, may cause the TPMS to malfunction and is therefore not recommended.
Verify the customer concern by inspecting the vehicle and observing the message center (if equipped)
and the TPMS indicator.
Training Known Good Sensors From Another Vehicle 1833

2. NOTE: The valve-mounted TPMS sensors and the strap-mounted TPMS sensors are not compatible.
Swapping wheels from one vehicle to another with the different systems will adversely affect TPMS
operation.
NOTE: Swapping wheels between vehicles with the same TPMS will cause a TPMS fault to be set if
the sensors are not trained. Refer to Tire Pressure Monitoring System (TPMS) Sensor Training in this
section.
NOTE: Non-OEM modifications made to the vehicle may result in false TPMS warnings.
Inspect to determine if one of the following mechanical or electrical concerns apply:
Low tire pressure Wiring, terminals or

Tire Pressure Monitoring System (TPMS) sensor damaged or missing connectors
Spare tire installed as a road wheel Smart Junction Box
Incorrect TPMS sensor installed (SJB)
TPMS sensor installed incorrectly Aftermarket
Sensors not trained after a tire rotation on vehicles with different front electronic accessories
and rear tire pressures
Non-OEM wheels installed (aftermarket rims)
Non-OEM equipped run-flat tires installed
Other non-OEM modifications (roll cages, service barriers, part racks,
ladder racks)


Using Customer's Electronics to Pinpoint the Radio Frequency Interference (RFI) Source 1834
418-00 .
(CMDTCs).
8. Clear the CMDTCs and carry out the self-test diagnostics for the SJB (the TPMS is part of the SJB ).
9. If the DTCs retrieved are related to the concern, go to the Tire Pressure Monitoring System (TPMS)
DTC Chart. For all other DTCs, refer to the Master DTC Chart in Section 419-10 .
DTC Charts
Tire Pressure Monitoring System (TPMS) DTC Chart
DTC Description Source Action

B106B Tire Pressure Sensor Smart DTC B106B can be set during SJB configuration. GO to
Low Battery Junction Pinpoint Test G .
Box (SJB)
B106D Tire Pressure SJB DTC B106D is only present when a new SJB is installed, the
Monitoring System SJB is incorrectly flashed or the SJB is incorrectly
(TPMS) Initiators Not configured. Successfully configuring the SJB is the only way
Configured to clear this DTC. VERIFY the SJB is correctly configured. If
DTC B106D is still present, REFER to Section 418-01 .
B2477 Module Configuration SJB DTC B2477 is only present when a new SJB is installed, the
Failure/Mismatch SJB is incorrectly flashed or the SJB is incorrectly
configured. Successfully configuring the SJB is the only way
to clear this DTC. MAKE SURE the SJB is configured
correctly. If DTC B2477 is still present, REFER to Section
418-01 .
B2868 LF Tire Pressure Sensor SJB DTC B2868 is only present when a new SJB is installed, the
Fault SJB is flashed or the SJB is reconfigured. TRAIN the tire
pressure sensors. REFER to Tire Pressure Monitoring System
(TPMS) Sensor Training in this section.
B2869 RF Tire Pressure Sensor SJB DTC B2869 is only present when a new SJB is installed, the
B2870 RR Tire Pressure Sensor SJB DTC B2870 is only present when a new SJB is installed, the
B2871 LR Tire Pressure Sensor SJB DTC B2871 is only present when a new SJB is installed, the
B2872 Tire Pressure Sensor SJB NOTE: If the vehicle has been stationary for more than 30
Fault minutes, the sensors will go into a "sleep mode" to conserve
battery power. It will be necessary to wake them up so they
will transmit the latest tire pressure information to the SJB .
ACTIVATE the TPMS sensors. REFER to Tire Pressure

Monitoring System (TPMS) Sensor Activation in this section.
GO to Pinpoint Test F .
B287A Tire Pressure System SJB GO to Pinpoint Test F .
Fault
C2780 ECU in Manufacturing SJB DTC C2780 is only present when a new SJB is installed, the
Mode SJB is flashed or the SJB is reconfigured. TRAIN the tire
U0155 Lost Communication SJB REFER to Section 418-00 to diagnose the no communication
with Instrument Cluster problem.
(IC)
All other - SJB REFER to the Master DTC Chart in Section 419-10 .
SJB
DTCs
Symptom Chart
Symptom Chart
NOTE: For vehicles with different front and rear tire pressures (such as E-Series and certain F-Series), the
tire pressures must be adjusted and the tire pressure sensors must be trained following a tire rotation. Failure
to train the sensors will result in a false low tire pressure event, which will cause the Tire Pressure Monitoring
System (TPMS) indicator to illuminate.
For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the system.
Failure of a TPMS component may not cause the message center to display a fault message or a DTC to be
stored. The Symptom Chart is a starting point to begin diagnosis of these concerns.
Tire Pressure Monitoring System (TPMS) indicator ON solid and message center (if equipped)
displays LOW TIRE PRESSURE
Spare tire currently in use
INSTALL the repaired road wheel/tire in place of the spare tire.
Air pressure not set to specifications listed on the Vehicle Certification (VC) label
Sensors not trained following tire rotation
ADVISE customer that on vehicles with different front and rear tire pressure, the sensors must be
trained as directed in the Owner's Literature.
Smart Junction Box (SJB) will not enter sensor training mode when using the TPMS sensor training
procedure
Brake ON/OFF switch
Ignition switch
Vehicle communication bus
SJB
GO to Pinpoint Test E .
TPMS indicator FLASHES for 70 seconds and then remains ON solid when the ignition key is turned
to the ON position, the message center (if equipped) displays TIRE PRESSURE SENSOR FAULT
and DTC B2872 is present
Intermittent TPMS operation due to Radio Frequency Interference (RFI)

TPMS sensors not trained
Not all TPMS sensors are installed
TPMS sensor(s)
SJB
NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep
mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest
tire pressure information to the SJB .
ACTIVATE the TPMS sensors. REFER to Tire Pressure Monitoring System (TPMS) Sensor
Activation in this section. GO to Pinpoint Test F .
to the ON position, the message center (if equipped) displays TIRE PRESSURE MONITOR FAULT
and DTC B287A is present
TPMS sensors not trained

NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep
mode" to conserve battery power. It will be necessary to wake them up so they will transmit the latest
tire pressure information to the SJB .
ACTIVATE the TPMS sensors. REFER to Tire Pressure Monitoring System (TPMS) Sensor
Activation in this section. GO to Pinpoint Test F .
to the ON position, the message center (if equipped) displays TIRE PRESSURE MONITOR FAULT
and there are no DTCs present
Vehicle communication issue between the SJB and the Instrument Cluster (IC)
REFER to Section 418-00 to diagnose the no communication concern.
SJB
REFER to Section 419-10 to diagnose the SJB .
One or more sensors will not train
TPMS sensor(s)
Vehicle communication issue
SJB
RETRIEVE and RECORD DTCs. REFER to Tire Pressure Monitoring System (TPMS) DTC Chart in
this section.
One or more sensors will not train and no DTCs are present
TPMS sensor(s)
Attempting to install a banded TPMS sensor that is not compatible with a valve mounted sensor
TRAIN all 4 tire pressure sensors. REFER to Tire Pressure Monitoring System (TPMS) Sensor
Training in this section.
If a sensor does not respond to the Tire Pressure Monitor Activation Tool, MOVE the vehicle to rotate
the wheels at least one-fourth of a turn and ATTEMPT to activate the same sensor again. If the sensor
still does not respond, ATTEMPT to activate the same sensor again using the customer activation tool
(if available). If the sensor still fails to train, ATTEMPT to train the sensor with the vehicle doors
open.
If the sensor(s) fails to train a second time, INSTALL a new sensor(s). REFER to Tire Pressure
Monitoring System (TPMS) Sensor in this section.
Pinpoint Tests
Pinpoint Test D: Tire Pressure Monitoring System (TPMS) Indicator ON Solid and Message Center (if
equipped) Displays LOW TIRE PRESSURE
Normal Operation
The Tire Pressure Monitoring System (TPMS) monitors the air pressure of all 4 road tires. The
wheel-mounted tire pressure sensors transmit via radio frequency signals, to the Smart Junction Box (SJB).
TPMS functionality is integral to the SJB . These transmissions are sent approximately every 60 seconds
when the vehicle speed exceeds 32 km/h (20 mph). The TPMS function (integral to the SJB ) compares each
tire pressure sensor transmission against a low-pressure limit. If it has been determined that the tire pressure
has fallen below this limit, the SJB communicates this on the vehicle communication bus to the Instrument
Cluster (IC). The IC then illuminates the TPMS indicator and displays the appropriate message(s) in the
message center (if equipped).
This symptom can also be caused by a spare tire currently being used in place of a road tire. Make sure that
the spare tire is not currently in use. On vehicles with different front and rear tire pressures, if the sensors are
not trained following a tire rotation, this symptom will also be present. Advise the customer that on vehicles
with different front and rear tire pressures, the sensors must be trained as directed in the Owner's Literature.

Low air pressure in tire(s)
Tire pressure sensor(s)
PINPOINT TEST D: TIRE PRESSURE MONITORING SYSTEM (TPMS) INDICATOR ON SOLID AND MESSAGE
CENTER (IF EQUIPPED) DISPLAYS LOW TIRE PRESSURE
NOTE: Use only the Digital Tire Gauge any time tire pressures are measured to be sure that accurate values
are obtained.

NOTE: If a warranty case is opened for an actual TPMS fault, document and include the actual tire pressure
data in all warranty communications.

D1 CHECK THE TIRE PRESSURE
Yes
Using the Digital Tire Gauge, The system is functioning normally, diagnosis is complete.
measure and record the air INFORM the customer of correct tire pressure maintenance
pressure in all 4 road tires. as instructed in the scheduled maintenance guide and the
Adjust the air pressure for those Owner's Literature.
found to be below the specification
listed on the Vehicle Certification No
(VC) label. GO to D2 .
NOTE: If the vehicle has been
stationary for more than 30
minutes, activate each TPMS
sensor. Refer to Tire Pressure
Monitoring System (TPMS)
Sensor Activation in this section.
The TPMS sensor does not
transmit when the vehicle is
stationary.
Verify system operation.
Have the TPMS indicator and
the message center (if equipped)
warnings gone out?
D2 CHECK THE SYSTEM
COMPONENTS
Yes
Train all 4 tire pressure sensors. The system is functioning normally, diagnosis complete.
Refer to Tire Pressure Monitoring
System (TPMS) Sensor Training in No
this section. Before installing a new sensor(s): If a sensor does not
Connect the scan tool. respond to the Tire Pressure Monitor Activation Tool,
Ignition ON. MOVE the vehicle to rotate the wheels at least one-fourth of
Enter the following diagnostic a turn and ATTEMPT to activate the same sensor again. If
mode on the scan tool: DataLogger the sensor still does not respond, ATTEMPT to activate the
- SJB . same sensor again using the customer activation tool (if
Read and record the following available). If the sensor still fails to train, ATTEMPT to train
PIDs: the sensor with the vehicle doors open.
Left Front Tire Pressure
(LF_PRES) INSTALL new tire pressure sensors for those with
Right Front Tire Pressure discrepancies or those that fail to activate. REFER to Tire
(RF_PRES) Pressure Monitoring System (TPMS) Sensor in this section.
Left Rear Outer Tire
Pressure (LRO_PRES)
Right Rear Outer Tire
Pressure (RRO_PRES)
Compare the air pressure readings
recorded from the function test to
those recorded in D1.
Do the compared tire pressure
values match within 5 psi, and
PINPOINT TEST D: TIRE PRESSURE MONITORING SYSTEM (TPMS) INDICATOR ON SOLID

1839
AND MES
have the TPMS indicator and

the message center (if equipped)
warnings gone out?
Pinpoint Test E: Smart Junction Box (SJB) Will Not Enter Sensor Training Mode When Using the Tire
Pressure Monitoring System (TPMS) Sensor Training Procedure
Normal Operation
For the Smart Junction Box (SJB) to enter Tire Pressure Monitoring System (TPMS) sensor training mode,
the SJB must receive valid inputs from the brake ON/OFF switch (OFF-ON-OFF) and ignition switch (both
OFF and RUN), and it must receive valid vehicle speed sensor input (0 km/h [0 mph]) from the Instrument
Cluster (IC). Refer to Tire Pressure Monitoring System (TPMS) Sensor Training in this section for the
complete sensor training procedure.

Brake ON/OFF switch
Ignition switch
SJB
PINPOINT TEST E: SMART JUNCTION BOX (SJB) WILL NOT ENTER SENSOR TRAINING MODE WHEN USING
THE TIRE PRESSURE MONITORING SYSTEM (TPMS) SENSOR TRAINING PROCEDURE

E1 CHECK THE SJB BRAKE ON/OFF
(GEM_BOO) PID
Yes
Connect the scan tool. GO to E2 .
Ignition ON.
Enter the following diagnostic mode on No
the scan tool: DataLogger - SJB . REFER to Section 417-01 to continue diagnosis of the
Monitor the GEM_BOO PID ( SJB stoplamp switch.
reads the brake switch directly).
Press and release the brake pedal while
monitoring the PID.
Do the brake pedal PID values match
the brake pedal positions?
E2 CHECK THE SJB IGNITION SWITCH
PIDs
Yes
Monitor the following ignition switch GO to E3 .
PIDs:
Ignition Switch Off No
(IGN_O_ECU) REFER to Section 211-05 to continue diagnosis of the
Ignition Switch RUN ignition switch.
(IGN_R_ECU)
Cycle the ignition switch to the RUN
and OFF position while monitoring the
PIDs ( SJB reads the ignition switch
directly).

Do the ignition switch status PID

values match the ignition switch
positions?
E3 CHECK THE SJB VEHICLE SPEED
SENSOR (VSS_GEM) PID
Yes
Monitor the VSS_GEM PID ( SJB GO to E4 .
receives vehicle speed from the IC ).
Is the vehicle speed less than 5 km/h No
(3 mph)? REFER to Section 413-01 to continue diagnosis of the
IC /vehicle speed concern.
E4 CHECK FOR CORRECT SJB
OPERATION
Yes
Check the connectors for: CLEAR the DTCs. REPEAT the self-test.
corrosion.
pushed-out pins. No
spread terminals. The system is operating correctly at this time. The
Connect all the SJB connectors and concern may have been caused by a loose or corroded
make sure that they are seated correctly. connector. CLEAR the DTCs. REPEAT the self-test.
Pinpoint Test F: TPMS Indicator FLASHES for 70 Seconds and Then Remains ON Solid When the
Ignition Key is Turned to the ON Position, the Message Center (if equipped) Displays TIRE
PRESSURE SENSOR or MONITOR FAULT and DTC B2872 or B287A is Present
Normal Operation
If there is a fault with 1, 2 or 3 of the Tire Pressure Monitoring System (TPMS) sensors, DTC B2872 sets.
The TPMS warning indicator flashes for 70 seconds and then remains ON continuously when the ignition
switch is turned to the ON position and the message center (if equipped) displays TIRE PRESSURE SENSOR
FAULT.
If the Smart Junction Box (SJB) does not get a response from all 4 of the TPMS sensors, DTC B287A sets
and the message center (if equipped) displays TIRE PRESSURE MONITOR FAULT.
It should be noted that TPMS communication can be interrupted by Radio Frequency Interference (RFI),
which can cause intermittent issues. RFI is generated by electrical motors and appliance operation, cellular
telephones, remote transmitters, power inverters and portable entertainment equipment. Anytime the TPMS
sensor training procedure is performed successfully, the warning indicator is extinguished and the vehicle
must be driven for 18-20 minutes before the SJB initiates a self test to verify system operation.
DTC B2872 (Tire Pressure Sensor Fault) - set by the SJB when 1, 2 or 3 of the tire pressure sensors
are faulted, not responding or when data is not received by the SJB .
DTC B287A (Tire Pressure Monitor Fault) - When all 4 of the tire pressure sensors are faulted, not
responding or when data is not received by the SJB .
TP_STAT PID = SYSTEM FAULT is displayed if the SJB does not receive a signal transmission
from all 4 TPMS sensors for 20 minutes and the vehicle speed is above 32 km/h (20 mph).
TP_STAT PID = SENSOR FAULT is displayed if the SJB does not receive a signal transmission
PINPOINT TEST E: SMART JUNCTION BOX (SJB) WILL NOT ENTER SENSOR TRAINING MODE
1841 WHEN
from 1, 2, or 3 TPMS sensors for 20 minutes and the vehicle speed is above 32 km/h (20 mph).

Intermittent TPMS operation due to RFI
TPMS sensor(s) not trained
TPMS sensor(s)
SJB
PINPOINT TEST F: TPMS INDICATOR FLASHES FOR 70 SECONDS AND THEN REMAINS ON SOLID WHEN THE
IGNITION KEY IS TURNED TO THE ON POSITION, THE MESSAGE CENTER (IF EQUIPPED) DISPLAYS TIRE
PRESSURE SENSOR OR MONITOR FAULT AND DTC B2872 OR B287A IS PRESENT

F1 CHECK THE HORN OPERATION
Yes
Press the steering wheel horn pad for GO to F2 .
2 seconds.
Does the horn sound? No
For horn diagnosis, REFER to Section 413-06 .
F2 CHECK THE TPMS STATUS
(TP_STAT) PID
Yes
NOTE: Make sure that all GO to F3 .
aftermarket electronic equipment has
been disconnected (if possible) and No
that the customer has been If the TP_STAT PID displays SYSTEM FAULT, GO to
questioned about the kinds of F5 .
electronic equipment they may have
been using in the vehicle when this
issue was identified.
Connect the scan tool.

NOTE: A spare tire cannot be
programmed to the vehicle, even if
equipped with a TPMS sensor. If a
damaged road wheel is located in the
trunk and the SJB cannot
communicate with it, or if the
damaged wheel has been dropped off
at a dealership or repair shop, the
SJB sets a TPMS sensor fault.
Ignition ON.
Enter the following diagnostic mode
on the scan tool: DataLogger - SJB .
Monitor the TP_STAT PID.
Does the PID display SENSOR
FAULT?
F3 CARRY OUT THE SENSOR
TRAINING PROCEDURE

Train all 4 tire pressure sensors. Yes

Refer to Tire Pressure Monitoring The system is operating correctly at this time. The concern
System (TPMS) Sensor Training in may have been caused by RFI . CLEAR the DTCs.
this section. REPEAT the self-test. TEST for normal operation.
Did all of the tire pressure sensors REFER to PID Definitions and Intermittent
transmit correctly and did the Troubleshooting in this section for information on locating
horn sound when each TPMS sources of RFI .
sensor transmitted to the SJB ?
No
GO to F4 .
F4 CHECK FOR CORRECT TPMS
OPERATION
Yes
Move the vehicle to rotate the If some of the TPMS sensors trained, INSTALL a new
wheels at least one-fourth of a turn. TPMS sensor for the TPMS sensor(s) that failed to train.
Leave the vehicle doors open. Start REFER to Wheel and Tire in this section. If all of the
the sensor training procedure at a TPMS sensors trained, the concern may have been cause
different wheel. by RFI . CLEAR the DTCs. REPEAT the self-test. TEST
Train all 4 tire pressure sensors. for normal operation. REFER to PID Definitions and
Refer to Tire Pressure Monitoring Intermittent Troubleshooting in this section for
System (TPMS) Sensor Training in information on locating sources of RFI .
this section.
Did any of the tire pressure No
sensors transmit correctly and did GO to F5 .
the horn sound when each TPMS
sensor transmitted to the SJB ?
F5 CHECK FOR CORRECT SJB
OPERATION
Yes
Disconnect all the SJB electrical NOTE: The sensors may not be present. DISMOUNT the
connectors. tire. REFER to Wheel and Tire in this section. VERIFY
Check the connectors for: the sensors are present and mounted to the wheels. If
corrosion missing, INSTALL new sensors.
pushed-out pins
bent pins If the sensors are present, INSTALL a new SJB . REFER
spread terminals to Section 419-10 . CLEAR the DTCs. REPEAT the
Connect all the SJB connectors and self-test.
make sure that they are seated
correctly. No
Operate the system and verify the The system is operating correctly at this time. The concern
concern is still present. may have been caused by a loose or corroded connector.
Is the concern still present? CLEAR the DTCs. REPEAT the self-test.
Pinpoint Test G: DTC B106B
Normal Operation
If there is a fault in the Tire Pressure Monitoring System (TPMS), such as a damaged or missing sensor(s),
damaged module or a communication issue within the vehicle, DTCs are set in the Smart Junction Box (SJB),
the TPMS warning indicator will flash for 70 seconds and then remain ON solid when the ignition switch is
turned to the ON position and the message center (if equipped) will display TIRE PRESSURE SENSOR
FAULT.
PINPOINT TEST F: TPMS INDICATOR FLASHES FOR 70 SECONDS AND THEN REMAINS ON
1843
SOLID W
The tire pressure sensor is battery powered.
This DTC may be set when attempting to train a tire pressure sensor(s) with a low battery.

Tire pressure sensor battery
Tire pressure sensor(s)
PINPOINT TEST G: DTC B106B

G1 DETERMINE WHICH
SENSOR HAS A LOW
BATTERY
Yes
Train all 4 tire pressure CLEAR the DTCs. REPEAT the self-test. VERIFY system operation.
sensors. Refer to Tire
Pressure Monitoring No
System (TPMS) Sensor Before installing a new sensor(s) : If a sensor does not respond to the
Training in this section. Tire Pressure Monitor Activation Tool, MOVE the vehicle to rotate the
Did all of the tire wheels at least one-fourth of a turn and ATTEMPT to activate the
pressure sensors same sensor again. If the sensor still does not respond, ATTEMPT to
transmit correctly and activate the same sensor again using the customer activation tool (if
did the horn sound available). If the sensor still fails to train, ATTEMPT to train the
when each tire sensor with the vehicle doors open.
pressure sensor
transmitted to the SJB If the sensor(s) fails to train a second time, INSTALL a new tire
? pressure sensor(s). REFER to Tire Pressure Monitoring System
(TPMS) Sensor in this section.

Tire Pressure Monitoring System (TPMS) Sensor Training
Special Tool(s)

204-363

NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to
conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure
information to the BCM . For additional information, refer to Tire Pressure Monitoring System (TPMS)
Sensor Activation in this section.
NOTE: The Tire Pressure Monitoring System (TPMS) Training procedure must be done on a single vehicle,
in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a Tire
Pressure Monitoring System (TPMS).
Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote
transmitters, power inverters and portable entertainment equipment.
NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, move the vehicle to rotate
the wheels at least one-fourth of a turn and attempt to activate the same sensor again. If the sensor still does
not respond, attempt to activate the same sensor again using the customer activation tool (if available). If the
sensor still fails to train, attempt to train the sensor with the vehicle doors open.
NOTE: The BCM has a 2-minute time limit between sensor responses. If the BCM does not recognize any 1
of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if
equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated.
NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the
tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS
indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation will not
affect the system.
1. NOTE: An animated version of this procedure is available on-line.
Turn the ignition switch to the OFF position, then press and release the brake pedal.
2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN
position.
3. Press and release the brake pedal.
4. Turn the ignition switch to the OFF position.
PINPOINT TEST G: DTC B106B 1845

5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN
position.
The horn will sound once and the TPMS indicator will flash if the training mode has been
entered successfully. If equipped, the message center will display TRAIN LF TIRE.
6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire
Pressure Monitor Activation Tool must remain in place at the valve stem.
Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall at the valve stem. Press and
release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to
indicate that the tire pressure sensor has been recognized by the BCM .
7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF
tire sidewall at the valve stem and press and release the test button to train the RF tire pressure sensor.
8. NOTE: Do not wait more than 2 minutes between training each sensor or the BCM will time out and
the entire procedure must be repeated.
Repeat Step 7 for the RR and LR tires.

The procedure is completed after the last tire has been trained. When the training procedure is
complete, the message center (if equipped) will display TIRE TRAINING COMPLETE.
For vehicles not equipped with a message center, successful completion of the training procedure will
be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn
sounds twice when the switch is turned to the OFF position, the training procedure was not successful.
9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the BCM and document
them on the applicable warranty claim.
10. NOTE: This step is required to clear DTC C2780, cause the BCM to exit the manufacturing mode
and to make sure there are no other concerns with a newly programmed BCM .
If the sensors are being trained due to the installation of a new BCM , clear any DTCs and carry out
the BCM On-Demand Self Test.
Tire Pressure Monitoring System (TPMS) Sensor Training 1846

Tire Pressure Monitoring System (TPMS) Sensor Training 1847

Tire Pressure Monitoring System (TPMS) Sensor Activation
Special Tool(s)

204-363, or Customer Activation Tool, Tire
Pressure Monitor
NOTE: The tire pressure sensors will go into a "sleep mode" when a vehicle is stationary to conserve battery
power. The sensors do not transmit information while in sleep mode. It will be necessary to wake them up so
they will transmit the latest tire pressure information.
1. Turn the ignition switch to the ON position.
2. Position the Tire Pressure Monitor Activation Tool against the LF tire sidewall at the tire valve stem.
3. NOTE: The Tire Pressure Monitor Activation Tool will provide feedback in the form of a flashing
green light and a beep sound for each successful response from a tire pressure sensor. This feedback
may not always be present, do not rely on it as a confirmation that the module heard a particular
sensor.
NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, move the vehicle
to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. If the
sensor still does not respond, attempt to activate the same sensor again using the customer activation
tool (if available). If the sensor still fails to train, attempt to train the sensor with the vehicle doors
open.
Press the test button on the Tire Pressure Monitor Activation Tool to activate the sensor. Activate the
sensor at least 2 times.
4. Repeat Steps 2 and 3 for the remaining tires.
5. If the Tire Pressure Monitoring System (TPMS) indicator remains illuminated after adjusting and
activating each sensor, refer to the Symptom Chart in Diagnosis and Testing in this section.
Tire Pressure Monitoring System (TPMS) Sensor Activation 1848

Tire Pressure Monitoring System (TPMS) Sensor Activation 1849

Wheel and Tire Rotation
NOTE: This procedure is intended for vehicles equipped with Tire Pressure Monitoring System (TPMS) and
different front and rear tire pressures.
1. Remove the wheel and tire assemblies. For additional information, refer to Wheel and Tire in this
section.
2. NOTE: The front tires are shown at the top of the illustration.
Rotate the wheel and tire assemblies as shown.
Cross the front tires and move them to the rear of the vehicle.
Move the rear tires (without crossing) to the front of the vehicle.
3. Install the wheel and tire assemblies. For additional information, refer to Wheel and Tire in this
section.
4. Adjust the tire pressures. For additional information, refer to the Vehicle Certification (VC) label
located on the driver door jamb.
5. NOTE: The tire pressures must be adjusted and the tire pressure sensors must be trained following a
tire rotation. Failure to train the sensors will result in a false low tire pressure event, which will cause
the TPMS indicator to illuminate.
Train the TPMS sensors. For additional information, refer to Tire Pressure Monitoring System
Wheel and Tire Rotation 1850

Wheel and Tire Rotation 1851

Wheel and Tire
Material
Item Specification
Lubricant
XL-2

1 1130 Center cap (if equipped)
2 1012 Wheel nut (6 required)
3 - Wheel and tire assembly
Removal
100-02 .
2. NOTICE: Do not use heat to loosen a seized wheel nut or damage to the wheel and wheel
bearing can occur.
Remove the 6 wheel nuts.
3. Remove the wheel and tire assembly.
Installation
1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign
material present on the mounting surface of theel and the mounting surface of the wheel hub,
brake drum or brake disc. Make sure that any fasteners that attach the rotor to the hub are
secured so they do not interfere with the mounting surfaces of the wheel. Failure to follow these
instructions when installing wheels may result in the wheel nuts loosening and the wheel coming
off while the vehicle is in motion, which could result in loss of control, leading to serious injury
or death to vehicle occupant(s).
Wheel and Tire 1852

NOTICE: Make sure to apply a thin coat of anti-seize lubrication only to the interface between
the wheel pilot bore and the hub pilot. Do not allow the anti-seize to make contact with the
wheel-to-brake disc/drum mounting surface, wheel studs, wheel nuts, brake pads or brake disc
friction surfaces or damage to components may occur.
Clean the wheel mounting surfaces and apply a thin coat of anti-seize to the wheel hub pilot surface
(wheel only).
2. Install the wheel and tire assembly.
3. WARNING: Retighten wheel nuts within 160 km (100 mi) after a wheel is reinstalled.
Wheels can loosen after initial tightening. Failure to follow this instruction may result in serious
injury to vehicle occupant(s).
NOTICE: Failure to tighten the wheel nuts in a star/cross pattern can result in high brake disc
runout, which will speed up the development of brake roughness, shudder and vibration.
NOTE: The wheel nut torque specification is for clean, dry wheel stud and wheel nut threads.
Install the 6 wheel nuts by hand.
Tighten the wheel nuts in a star/cross pattern.

Wheel and Tire 1853

Wheel and Tire
Special Tool(s)

204-354
Part
1 1508 Tire
2 1007 Wheel
3 1700 Valve stem and screw (also part of 1A189)
4 1A189 Tire Pressure Monitoring System (TPMS) sensor (a new
sensor assembly includes W714266 screw and 1700 valve
stem and cap)
5 - Valve stem-to- TPMS sensor screw (part of 1700)
6 1A163 Valve stem cap (also part of 1A189)
Disassembly
WARNING: The tire pressure monitoring system (TPMS) sensor battery may release hazardous
chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes, flush
immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of
the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the
correct procedures for hazardous material disposal. Failure to follow these instructions may result in
NOTICE: Failure to follow the instructions below may result in damage to the Tire Pressure
Monitoring System (TPMS) sensor.
NOTICE: The Tire Pressure Monitoring System (TPMS) sensor is mounted to the valve stem. Removal
of the valve stem requires dismounting the tire from the wheel and removal of the TPMS sensor.
Wheel and Tire 1854

NOTE: Use only the Digital Tire Pressure Gauge any time tire pressures are measured to be sure that accurate
values are obtained.
1. Remove the wheel and tire. For additional information, refer to Wheel and Tire in this section.
2. NOTICE: The valve stem is connected to the Tire Pressure Monitoring System (TPMS) sensor.
Do not pull the valve stem from the wheel, or damage to the sensor will occur.
Remove the valve stem core and fully deflate all air from the tire.
If a new Tire Pressure Monitoring System (TPMS) sensor is being installed, remove and
discard the valve stem-to-sensor screw and the sensor.
NOTICE: Do not allow the tire beads to move beyond the wheel mid-plane (middle of the wheel) when
separating the beads from the wheels, damage to the Tire Pressure Monitoring System (TPMS) sensor
may occur.
3. NOTICE: Tire and valve stem position is critical to prevent damage to the Tire Pressure
Monitoring System (TPMS) sensor when using a paddle-type bead separator.
NOTE: Some machines may have a nylon roller bead separator at the 12 o'clock position instead of
the paddle-type bead separator at the 3 o'clock position.
Position the wheel and tire assembly on a suitable tire machine and separate both beads of the tire
from the wheel.
For a paddle-type tire machine, position the valve stem at the 12 o'clock or 6 o'clock position
and the paddle at the 3 o'clock position.
For a roller-type tire machine, align the valve stem with the roller at any position.
4. NOTE: Index-mark the valve stem and wheel weight positions on the tire.
Place the wheel and tire assembly on the turntable of the tire machine with the valve stem at the 11:30
position and the machine arm at the 12 o'clock position and dismount the outer bead from the wheel.
Wheel and Tire 1855

5. Reset the wheel and tire assembly on the turntable of the tire machine with the valve stem at the 11:30
position and the machine arm at the 12 o'clock position and dismount the inner bead from the wheel.
6. NOTE: A new valve stem must be installed whenever a new tire or wheel is installed.
Remove the TPMS sensor in the following sequence.
1. Using a T10 Torx, remove the valve stem-to- TPMS sensor screw.
2. Carefully and firmly, pull the sensor straight down and separate it from the valve stem.
7. NOTICE: Use care not to damage the wheel surface when removing the valve stem.
Using a suitable valve stem puller and a wood block, remove the valve stem from the wheel.
8. NOTE: When installing a new wheel, always install a new valve stem and sensor screw. Reuse the
TPMS sensor from the previous wheel if possible. The TPMS will not have to be trained if the sensor
is reused.
If the TPMS sensor is being reused, inspect the TPMS sensor for damage and install a new sensor as
necessary.
Assembly
NOTICE: Damage to the Tire Pressure Monitoring System (TPMS) sensor may result if the tire
mounting is not carried out as instructed.
Wheel and Tire 1856

1. NOTICE: To prevent Tire Pressure Monitoring System (TPMS) sensor and valve stem damage,
the valve stem must be installed onto the TPMS sensor and then installed into the wheel as an
assembly.
Install a new valve stem onto the TPMS sensor.
Tighten the new valve stem-to- TPMS sensor screw to 1.5 Nm (13 lb-in).
2. NOTICE: It is important to pull the valve stem and Tire Pressure Monitoring System (TPMS)
sensor assembly through the wheel rim hole in a direction parallel to the valve stem hole axis. If
the assembly is pulled through at an angle, damage to the valve stem and sensor assembly may
occur.
NOTICE: Use care not to damage the wheel surface when installing the valve stem and Tire
Pressure Monitoring System (TPMS) sensor assembly.
Lubricate the valve stem with soapy water and install the valve stem and TPMS sensor assembly into
the wheel using a block of wood and a suitable valve stem installer.
3. Make sure the valve stem rubber is fully seated against the wheel.
4. NOTE: Lubricate the tire beads using a suitable fast-drying, corrosion-inhibiting tire bead lubricant.
NOTE: Do not mount the tire at this time.
Position the wheel on the turntable of the tire machine, then lubricate and position the bottom bead of
the tire on the wheel.
5. Position the wheel to align the valve stem with the machine arm, at the 6 o'clock position, and mount
the bottom bead of the tire.
Wheel and Tire 1857

6. Reposition the wheel to align the valve stem with the machine arm at the 6 o'clock position, and
mount the top bead of the tire.
7. NOTE: Use only the Digital Tire Pressure Gauge any time tire pressures are measured to make sure
that accurate values are obtained.
Inflate the tire to the pressure specified on the Vehicle Certification (VC) label located on the driver
door or door pillar.
Proceed to Step 8 if the tire beads do not seat at the specified inflation pressure.
8. WARNING: If there is a need to exceed the maximum pressure indicated on the sidewall of
the tire in order to seat the beads, follow all steps listed below. Failure to follow these steps may
The following steps should only be carried out if the tire beads cannot be seated by inflating the
tire up to the maximum inflation pressure listed on the tire sidewall.
1. Relubricate the tire bead and wheel bead seat area.

2. Install a remote valve and pressure gauge.
3. Wear eye and ear protection and stand at a minimum of 3.65 m (12 ft) away from the wheel
and tire assembly.
4. Inflate the tire using the remote valve and tire gauge until the beads have seated or until the
pressure gauge is 138 kPa (20 psi) more than maximum inflation pressure on tire sidewall. If
beads have not seated, deflate the tire and proceed to the next step.
5. Place the wheel and tire assembly in an OSHA-approved tire safety cage.
6. Inflate the tire using the remote valve and pressure gauge until the beads have seated or until
the pressure gauge is 276 kPa (40 psi) more than maximum inflation pressure on the tire
sidewall. Do not exceed 276 kPa (40 psi) above the maximum pressure on tire sidewall.
Install a new tire if the beads do not seat at this pressure.
9. Install the wheel and tire. For additional information, refer to Wheel and Tire in this section.
Wheel and Tire 1858

Wheel and Tire 1859


SECTION 204-04: Wheels and Tires
Manual
SUBASSEMBLIES
Tire Pressure Monitoring System (TPMS) Sensor
Disassembly
1. NOTE: The Tire Pressure Monitoring System (TPMS) sensor cannot be removed without
disassembly of the wheel and tire.
Disassemble the wheel and tire. For additional information, refer to Wheel and Tire in this section.
Tire Pressure Monitoring System (TPMS) Sensor 1860

SECTION 204-05: Vehicle Dynamic Suspension 2011 Expedition, Navigator Workshop Manual
Material

Capacity
XG-4 and/or XL-5
Dielectric Compound
XG-3-A

Air compressor bracket bolts 15 - 133
Compressor drier screw 3 - 27
Height sensor ball stud 20 - 177
Height sensor bolts 11 - 97
Shock absorber lower bolt 475 350 -
Shock absorber rod nut 45 33 -
Shock absorber upper nuts 40 30 -
Upper mount screws 4 - 35
Tire Pressure Monitoring System (TPMS) Sensor 1861

Vehicle Dynamic Suspension
The rear air suspension system is comprised of the following components:
Message center
Vehicle Dynamics Module (VDM)
Two suspension ride height sensors
Compressor and drier assembly (includes vent solenoid)
Air tubes
Rear air spring and shock absorber assemblies
Two air spring solenoid valves
Compressor relay
Air Suspension System Operation
The rear wheel air suspension system operates in the following manner:
Vehicle height is controlled by the VDM .

Each air spring has a solenoid that must open to vent (or compress).
The air suspension compressor has a vent solenoid that must open to vent the system.
The rear air springs raise or vent together.
The system does not operate when:
any of the doors are open.
the liftgate or liftgate glass is open.
the power running boards are deployed.
The system will vent/compress when the vehicle speed exceeds 24 km/h (15 mph) even if the air
suspension has been set to the OFF position.
Trim height is normal driving height.
The height sensor:
system uses RH and LH rear height sensors.
output voltage is between 0.5 and 4.5 volts.
voltage output decreases (goes from high to low) as the suspension system raises the vehicle.
The suspension ride height changes when:
the key is in the ON position, the load leveling feature automatically makes adjustments to the
vehicle height so that the vehicle is always at target height and constant front-to-rear vehicle
attitudes are maintained over the load range of the vehicle.
the key is in the OFF position. The system will remain active for 40 minutes after the ignition
is turned off, allowing the system to deflate (vent) at any time while allowing the system to
inflate (pump) only once at the end of 40 minutes.
Air Suspension Pneumatic Diagram
Vehicle Dynamic Suspension 1862


1 5319 Air compressor and drier
2 5B321 Air line union
3 - Air line Y-fitting
4 18945/5311 Air springs and solenoids
Air Suspension Pneumatic Diagram 1863

Vehicle Dynamic Suspension
Special Tool(s)
Flex Probe Kit


Vacuum Tester or equivalent

014-R1054

WARNING: Vent all air pressure from the air suspension system prior to disconnecting or
removing any air suspension components. It is dangerous to remove air suspension components while
under pressure. Failure to follow this instruction may result in serious personal injury.
WARNING: Always inflate air springs before loading the suspension. If a load is applied to an
uninflated air spring, the spring may be damaged and a new air spring will have to be installed.
Damaged springs degrade vehicle handling, which could result in serious injury to vehicle occupant(s).
WARNING: Inspect the air spring for correct shape after it has been inflated with the wheels off the
ground and the suspension unloaded. A deformed air spring could fail. Failure to follow this instruction
may result in serious injury to the technician or vehicle occupant(s).
The air suspension system is designed to improve ride handling and general vehicle driving performance. A
microprocessor controls the air suspension system. The microprocessor and the supporting hardware are
contained in the Vehicle Dynamics Module (VDM). The VDM responds to signals from various sensors in the
vehicle to maintain the programmed ride height while the vehicle is either moving or stopped. This is
accomplished by opening and closing the solenoid valves to control the amount of air in the air spring(s). The
VDM controls the air compressor by applying voltage through the compressor relay to inflate the air spring(s)
and raise the vehicle. The VDM opens the vent solenoid to lower the vehicle by releasing air from the air
spring(s) in response to signal inputs from the air suspension height sensor. The VDM has a preprogramming
trim height.

The load leveling feature automatically makes adjustments in vehicle height so that the vehicle is always at
target height and constant front-to-rear vehicle attitudes are maintained over the load range of the vehicle.
The system will remain active for 40 minutes after the ignition is turned off to make limited height
adjustments as necessary.
Air Suspension Disable Feature
The air suspension system can be disabled through the message center. Refer to Air Suspension System
Disable/Enable in this section. When the driver elects to disable the air suspension system, the message center
sends a message over the High Speed Controller Area Network (HS-CAN) bus to the VDM . Once the
message is received, the VDM will take no further action to inflate or deflate the air springs, below 15 mph.
The system will remain ON or OFF when the ignition key is cycled.
When the air suspension system has been disabled, the message center will display SUSPENSION
SWITCHED OFF.
Air Compressor
The air compressor:
consists of the compressor and vent solenoid; neither are serviced as individual items.
is a single cylinder electric motor driven unit that provides pressurized air as required.
is powered by an electromechanical relay, which is controlled by the VDM .
passes pressurized air through the compressor air drier that contains silica gel (a drying agent).
Moisture is then removed from the compressor air drier when vented air passes out of the system
during vent operation.
has a single port drier that can be serviced separately.
The vent solenoid:
allows air to escape from the system during venting actions.

is part of the air compressor cylinder head.
shares a common electrical connector with the air compressor motor.
is enclosed in the cylinder head casting and forms an integral valve housing.
has an O-ring seal that prevents air leakage past the dryer tip.
opens when the VDM determines that lowering is required.
provides an escape route for pressurized air when system pressures exceed safe operating levels.
has a 1,034 kPa (150 psi) internal relief valve.
is installed with the air compressor as a unit.
Air Spring
The air suspension system has 2 rear air springs. The air springs provide a varying spring rate proportional to
the system air pressure and volume. The air suspension system regulates the air pressure in each air spring by
compressing and venting the air. Increasing air pressure (compressing) raises the vehicle; decreasing air
pressure (venting) lowers the vehicle. Vehicle height is maintained by the addition and removal of air in each
air spring through an air spring solenoid installed in the upper spring cap and energized through the VDM .
Air Tubes and Fittings
NOTE: Apply a soapy water solution to the air tubes to verify the location of air leaks. If the air tubes are cut,
ruptured or leaking, a service repair kit is available.

Nylon air tubes with quick connect fittings connect to the air compressor and air spring solenoids. A Y-fitting
is also used to divide the air supply to the RH and LH air spring solenoids.
Air Suspension Height Sensors
There are 2 suspension height sensors used for the rear suspension. The sensors send a voltage signal to the
VDM . The output ranges from approximately 4.5 volts at minimum height (when the vehicle is low or in full
jounce) to 0.5 volt at maximum height (when the vehicle is high or in full rebound).
The sensors have a usable range of 45 degrees. The sensors are mounted to the suspension at a point where
full suspension travel at the wheel is relative to the travel at the height sensor. The sensors are mounted to the
frame and the link is attached to a ball stud on the lower suspension arm. The left and right sensors have
opposite polarity and are not interchangeable.
When the height sensor indicates that the vehicle is lower than trim under normal driving conditions, the air
compressor will turn on and pump compressed air to the system. When the sensor indicates that the vehicle is
raised above trim under normal driving conditions, this will cause the air to be vented from the system to
lower the vehicle to the trim height level.
Compressor Relay
An electromechanical relay is used in the air suspension system for compressor control. The relay switches
high current loads in response to low power signals and is controlled by the VDM .
The compressor relay is energized by the VDM to have high current flow from the battery to the compressor
motor.
NOTICE: The Vehicle Dynamics Module (VDM) mut receive a ride height adjustment calibration and
pass a pneumatic test when it is installed new or swapped. Failure to follow these instructions will result
in the air suspension system operating incorrectly.
The VDM controls the air compressor motor (through an electromechanical relay), all air spring solenoids and
provides power to the rear height sensors. The VDM also controls vehicle height adjustments by monitoring
the 2 height sensors and other HS-CAN messages. The VDM conducts all fail-safe and diagnostic strategies
and contains self-test and communication software for testing the vehicle and related components.
The VDM monitors and controls the air suspension system through an 8-pin connector and a 16-pin
connector. The connectors and the VDM are keyed so that the connectors cannot be plugged in incorrectly.
The VDM uses the HS-CAN communications network for sending and receiving various information.
Air Spring Solenoid
The air spring solenoid:
allows air to enter and exit the air spring during leveling operations.
is electrically operated and controlled by the VDM .
is serviced separately from the air spring.

2. NOTE: If the door ajar indicator is illuminated when all the doors, the liftgate and the liftgate glass
are closed, the air suspension will not work correctly. Repair the door ajar indicator. Refer to Section
413-01 .
Visually inspect for obvious signs of mechanical and electrical damage.
Restricted suspension movement Battery Junction Box (BJB) fuses:

Excessive vehicle load 19 (60A)
Damaged or disconnected air tube(s) and/or 48 (30A)
fitting(s) 53 (10A)
Unmounted or damaged height sensor(s) Wiring, terminals or connectors
Damaged rear air spring(s) Damaged Vehicle Dynamics Module
Damaged solenoid valve(s) (VDM)
check the VDM connection to the vehicle.

check the scan tool connection to the VDM .


418-00 .
If the network test passes, retrieve and record continuous memory DTCs.

8. Clear the continuous DTCs and carry out the self-test diagnostics for the VDM . Refer to Self-Test in
this section.
9. If the DTCs retrieved are related to the concern, go to Vehicle Dynamics Module (VDM) DTC Chart.
For all other DTCs, refer to the Master DTC Chart in Section 419-10 .
Pneumatic Test
This test verifies that the air tubes are connected and that they are not restricted. It also verifies that the air
compressor, air compressor vent solenoid and air spring solenoid valves are functioning correctly. This test is
used to clear DTCs C1990 and C1991. Verify that the following conditions are met before running the
Pneumatic Test.
All the doors, the liftgate and the liftgate glass must be closed.
The transmission is in PARK.
The vehicle speed is less the 10 km/h (6 mph).
The ignition switch is in the ON position.
The air suspension system is enabled.
Battery voltage is greater than 11 volts for the duration of the test.
1. Fulfill the pre-conditions.
2. Install a battery charger for the Pneumatic Test to prevent battery drain.
3. Using the scan tool, carry out the Pneumatic Test.
Trim Height Test (or Accurate Trim Test)
NOTE: The Trim Height Test is used to verify trim height only. If trim height needs to be adjusted, refer to
Ride Height Adjustments in this section.
The trim height test is used to make the vehicle level to within 2 mm (0.08 in) of the calibrated trim height.
An accurate trim test should be run before setting vehicle alignment.
The following conditions must be met for the trim height test to run:
All the doors, the liftgate and the liftgate glass must be closed.
The vehicle speed is less than 10 km/h (6 mph).
The air suspension system is enabled.
Battery voltage is greater than 11 volts for the duration of the test.
2. Install a battery charger for the Trim Height Test to prevent battery drain.
3. Using the scan tool, carry out the Trim Height Test.

Self-Test
Verify that the following conditions are met before running the On-Demand Self Test.
All doors, the liftgate and the liftgate glass must be closed.
The vehicle speed is less than 10 km/h (6 mph).
2. Install a battery charger for the On-Demand Self Test to prevent battery drain.
3. Carry out the Vehicle Dynamics Module (VDM) On-Demand Self Test.
4. Record all listed DTCs.
5. Retrieve stored DTCs.
6. Troubleshoot any On-Demand Self Test DTCs first.
7. Repeat the On-Demand Self Test and clear DTCs after repairs are completed.
Vehicle Dynamics Module (VDM) DTC Chart
NOTE: Repair all other DTCs before repairing C1726. Repair DTCs C1990 and C1991 last.
DTCs Description Action

B1317 Battery Voltage High GO to Pinpoint Test A .
B1318 Battery Voltage Low GO to Pinpoint Test A .
B1342 ECU is Faulted INSTALL a new VDM . REFER to Vehicle Dynamics Module
(VDM) in this section. SET the ride height. REFER to Ride Height
Adjustments in this section. CARRY OUT the Pneumatic Test.
B1566 Door Ajar Circuit Short to Doors/running boards open during self-test. VERIFY doors/running
Ground boards signals are working. REFER to Section 417-02 for door ajar
switch diagnosis and Section 501-08 for retractable running board
diagnosis.
B2477 Module Configuration Failure INSTALL a new VDM . REFER to Vehicle Dynamics Module
(VDM) in this section. SET the ride height. REFER to Ride Height
Adjustments in this section. CARRY OUT the Pneumatic Test.
C1724 Air Suspension Height Sensor GO to Pinpoint Test B .
Power Circuit Failure
C1726 Air Suspension Rear GO to Pinpoint Test C .
Pneumatic Failure
C1770 Air Suspension Vent Solenoid GO to Pinpoint Test D .
Output Circuit Failure

C1790 Air Suspension LR Air Spring GO to Pinpoint Test E .

Solenoid Output Circuit
Failure
C1795 Air Suspension RR Air Spring GO to Pinpoint Test E .
Solenoid Output Circuit
Failure
C1810 Air Suspension Height Sensor GO to Pinpoint Test K .
Delta Out of Range
C1830 Air Suspension Compressor GO to Pinpoint Test J .
Relay Circuit Failure
C1885 Air Suspension RR Height GO to Pinpoint Test F .
Sensor Circuit Failure
C1893 Air Suspension LR Height GO to Pinpoint Test F .
Sensor Circuit Failure
C1990 New Control Module REFER to Clearing DTC C1990 or C1991.
Initialization (requires ride
height calibration and
pneumatic test pass)
C1991 Plant Ride Height Setting REFER to Clearing DTC C1990 or C1991.
and/or Tests Incomplete
C1964 Compressor Run Time GO to Pinpoint Test J .
Exceeded
C2001 Ride Height Calibration Error ADJUST the ride height, REFER to Ride Height Adjustments in this
section. CLEAR the DTCs. REPEAT the self-test.
C2002 Pneumatic Test Failure VERIFY that all Pneumatic Test pre-conditions are met, REFER to
Pneumatic Test in this section. REPEAT the Pneumatic Test. If all
conditions are met, the scan tool can communicate with the VDM
and the module and is still unable to complete the Pneumatic Test,
U0073 Control Module REFER to Section 418-00 to diagnose the High Speed Controller
Communication Bus A Off Area Network (HS-CAN) bus.
U0100 Lost Communication with REFER to Section 418-00 to diagnose the HS-CAN bus.
Powertrain Control Module
(PCM)
Body Control Module
Instrument Cluster
U2011 Module Transmitted Invalid CLEAR the DTC. REPEAT the self-test.
Data
If DTC U2011 returns, INSTALL a new VDM . REFER to Vehicle
Dynamics Module (VDM) in this section. CLEAR the DTC.
U2050 Application Not Present INSTALL a new VDM . REFER to Vehicle Dynamics Module
(VDM) in this section. CLEAR the DTC. REPEAT the self-test.
Clearing DTCs C1990, C1991, C2001 and C2002

NOTE: Before proceeding with the following steps, make sure that the air suspension system is fully
functional. The vehicle must pass the Pneumatic Test and have both ride height sensors calibrated for these
codes to clear.
1. Connect the scan tool to the vehicle.
2. If DTC C1990 or DTCs C1991 and C2002 are present, carry out the Pneumatic Test. The tester will
indicate if the vehicle has passed the test.
3. NOTE: The vehicle must be on a level surface before calibrating the ride height sensors. Failure to
follow this instruction will result in system malfunction.
If DTC C1990 or DTCs C1991 and C2001 are present, use the scan tool to manually raise and lower
the vehicle to the correct ride height on an alignment machine and calibrate the ride heights. Refer to
Ride Height Adjustments in this section.
4. Using the scan tool, retrieve the DTCs. Verify that all DTCs have been cleared.
5. Drive the vehicle and verify the repair. Verify that the message center does not display "Check
Suspension".
Symptom Chart
Symptom Chart
Pinpoint Tests
NOTICE: Electronic modules are sensitive to electrostatic discharge. If exposed to these charges,
damage to the module may result.
Refer to Inspection and Verification, the Vehicle Dynamics Module (VDM) DTC Chart and the Symptom
Chart in this section for direction to the appropriate pinpoint test.
Pinpoint Test A: DTC B1317 or B1318
Refer to Wiring Diagrams Cell 41 , Vehicle Dynamic Suspension for schematic and connector information.
Normal Operation
The Vehicle Dynamics Module (VDM) is supplied fused battery voltage through Battery Junction Box (BJB)
fuse 48 (30A) along circuit SBB48 (VT/RD), and fused ignition voltage through BJB fuse 53 (10A) along
circuit CBB53 (GY/BN). A ground path is provided along circuit GD120 (BK/GN).
DTC B1317 Battery Voltage High - With the ignition key in the RUN position, if battery voltage
exceeds 18 volts for more than 500 milliseconds, DTC B1317 will be set.
DTC B1318 Battery Voltage Low - With the ignition key in the RUN position, if battery voltage falls
below 8.5 volts for more than 500 milliseconds, DTC B1318 will be set.

Fuse(s)

VDM
PINPOINT TEST A: DTC B1317 OR B1318
NOTICE: Use the Flex Probe Kit for all test connections to prevent damage to the wiring terminals. Do
not use standard multi-meter probes.

A1 CHECK FOR ACTIVE DTCs
Yes
Repeat the self-test. GO to A2 .
Are the DTCs active?
No
The system is operating correctly at this time.
Concern may have been caused by low battery or
charging system voltage. VERIFY that the battery
and charging system are OK. REFER to Section
414-00 .
A2 CHECK THE BATTERY VOLTAGE
Yes
Measure the battery voltage between the GO to A3 .
positive and negative battery posts with
the Key ON Engine OFF (KOEO) and No
with the engine running. REPAIR the battery or charging system. REFER to
Is the battery voltage between 10 and 13 Section 414-00 . TEST the system for normal
volts with KOEO and between 11 and operation.
16 volts with the engine running?
A3 CHECK FOR VOLTAGE TO THE VDM
Yes
Disable the air suspension system. Refer to GO to A4 .
Air Suspension System Disable/Enable in
this section. No
Ignition OFF. VERIFY BJB fuses 53 (10A) and 48 (30A) are OK.
Disconnect: VDM C2131a. If OK, REPAIR the affected circuit(s). If not OK,
Ignition ON. REFER to the Wiring Diagrams manual to identify
Both with the KOEO and with the engine the possible causes of the circuit short. CLEAR the
running, measure the voltage between DTCs. REPEAT the self-test.
ground and:
VDM C2131a-3, circuit CBB53
(GY/BN), harness side.
VDM C2131a-11, circuit SBB48
(VT/RD), harness side.
VDM C2131a-12, circuit SBB48
(VT/RD), harness side.
PINPOINT TEST A: DTC B1317 OR B1318 1872

Is the voltage between 10 and 13 volts

with KOEO , and between 11 and 16
volts with the engine running?
A4 CHECK CIRCUITS GD133 (BK) AND
GD120 (BK/GN) FOR AN OPEN
Yes
Measure the resistance between ground
and: No
VDM C2131a-5, circuit GD120 REPAIR the affected circuit(s). CLEAR the DTCs.
(BK/GN), harness side. REPEAT the self-test.
VDM C2131a-14, circuit GD120
(BK/GN), harness side.

A5 CHECK THE VDM CONNECTOR
Yes
Check VDM C2131a for: INSTALL a new VDM . REFER to Vehicle
corrosion. Dynamics Module (VDM) in this section. CLEAR
pushed-out pins. the DTCs. REPEAT the self-test.
spread terminals.
Connect: VDM C2131a. No
Make sure the connector is seated The system is operating correctly at this time.
correctly then operate the system and Concern may have been caused by a loose or
verify the concern is still present. corroded connector.
Pinpoint Test B: DTC C1724
Normal Operation
The 2 rear height sensors receive a 5-volt reference voltage from the Vehicle Dynamics Module (VDM) along
circuit LCL12 (VT/OG), both sensors share a common return path along circuit RCL12 (GN/WH). The RR
sensor sends the suspension height voltage back to the VDM along circuit VCL12 (WH/VT) and the LR
sensor sends the suspension height voltage back to the module along circuit VCL13 (BN/BU). The VDM
monitors the 2 height sensors and makes adjustments to the rear suspension based on sensor input.

DTC C1724 (Air Suspension Height Sensor Power Circuit Failure) - This DTC can be set during
normal operation and during the VDM on-demand self test. DTC C1724 will set during normal
operation if the ignition key is in the RUN position and the height sensor supply voltage is not at the
expected level for more than 2 minutes. DTC C1724 will set during the on-demand self test if the
height sensor voltage is not detected after being enabled during the test.

Height sensor(s)
VDM
PINPOINT TEST B: DTC C1724

B1 CHECK THE AIR SUSPENSION HEIGHT SENSOR
VOLTAGE PIDs
Yes
Disable the air suspension system. Refer to Air INSPECT the height sensor electrical
Suspension System Disable/Enable in this section. connectors for corrosion and damage,
Connect the scan tool. REPAIR as necessary. CLEAR the
DataLogger VDM . No
Disconnect the sensor arm linkage from both rear air CONNECT the sensor arm linkages to
suspension height sensors. the height sensors.
NOTE: The voltage will increase as the suspension is
compressed. For the LR height sensor, GO to B2 .
Slowly move the height sensors through their full range
of travel up and down while monitoring the following For the RR height sensor, GO to B3 .
PIDs:
Left Rear Height Sensor Voltage
(LR_HEIGHT)
Right Rear Height Sensor Voltage
(RR_HEIGHT)
Do the voltages vary from approximately 0.50 volt
and 4.50 volts?
B2 CHECK FOR VDM OUTPUT (LR HEIGHT SENSOR
VOLTAGE)
Yes
Disconnect: LR Height Sensor C4092.
Ignition ON. No
Measure the voltage between LR height sensor If less than 5 volts are present, GO to
C4092-3, circuit LCL12 (VT/OG), harness side and B4 . If more than 5 volts are present,
ground. GO to B6 .
PINPOINT TEST B: DTC C1724 1874

Are 5 volts present?

B3 CHECK FOR VDM OUTPUT (RR HEIGHT SENSOR
VOLTAGE)
Yes
Disconnect: RR Height Sensor C4093.
Ignition ON. No
Measure the voltage between RR height sensor If less than 5 volts are present, GO to
C4093-3, circuit LCL12 (VT/OG), harness side and B4 . If more than 5 volts are present,
ground. GO to B6 .

B4 CHECK CIRCUIT LCL12 (VT/OG) FOR AN OPEN
Yes
Disconnect: VDM C2131b.
For the RR height sensor , measure the resistance No
between VDM C2131b-4, circuit LCL12 (VT/OG), REPAIR circuit LCL12 (VT/OG).
harness side and RR height sensor C4093-3, circuit CLEAR the DTCs. REPEAT the
LCL12 (VT/OG), harness side. self-test.
For the LR height sensor , measure the resistance
between VDM C2131b-4, circuit LCL12 (VT/OG),
harness side and LR height sensor C4092-3, circuit
LCL12 (VT/OG), harness side.

B5 CHECK CIRCUIT LCL12 (VT/OG) FOR A SHORT
TO GROUND
PINPOINT TEST B: DTC C1724 1875

For the RR height sensor , measure the resistance Yes

between RR height sensor C4093-3, circuit LCL12 GO to B7 .
(VT/OG), harness side and ground.
For the LR height sensor , measure the resistance No
between LR height sensor C4092-3, circuit LCL12 REPAIR circuit LCL12 (VT/OG).
(VT/OG), harness side and ground. CLEAR the DTCs. REPEAT the
self-test.

B6 CHECK CIRCUIT LCL12 (VT/OG) FOR A SHORT
TO VOLTAGE
Yes
Ignition OFF. REPAIR circuit LCL12 (VT/OG).
Disconnect: VDM C2131b. CLEAR the DTCs. REPEAT the
For the LR height sensor, measure the voltage
between LR height sensor C4092-3, circuit LCL12 No
(VT/OG), harness side and ground. GO to B7 .
For the RR height sensor, measure the voltage
between RR height sensor C4093-3, circuit LCL12
B7 CHECK THE VDM CONNECTOR
Yes
Ignition OFF. INSTALL a new VDM . REFER to
Disconnect: VDM C2131b. Vehicle Dynamics Module (VDM) in
Check the VDM connector for: this section. CLEAR the DTCs.
pushed-out pins.
spread terminals. No
Connect: VDM C2131b. The system is operating correctly at this
Make sure the connector is seated correctly, then time. Concern may have been caused by
operate the system and verify the concern is still a loose or corroded connector.
present.
Pinpoint Test C: Vehicle Raises and/or Lowers Too Slowly or Uneven Vehicle Height
Normal Operation
The air suspension height sensor sends a voltage signal to the Vehicle Dynamics Module (VDM). The output
ranges from approximately 4.5 volts at minimum height (when the vehicle is low or in full jounce) to 0.5 volt
at maximum height (when the vehicle is high or in full rebound).

When the suspension height sensor indicates that the rear of the vehicle is lower or higher than trim height
under normal driving conditions, the VDM will command the air compressor and air solenoid valves to either
fill or vent the air springs depending on the input from the 2 height sensors. The air compressor sends the air
to the air springs first through the drier then along the air tubes, passing through a Y-fitting and connections,
through the air solenoid valves and finally to the air springs.
DTC C1726 (Air Suspension Rear Pneumatic Failure) - With the ignition key in the RUN position,
DTC C1726 will be set if the air suspension system attempts and fails to inflate (pump) or deflate
(vent) a specified number of times.
DTC C2002 (Pneumatic Test Failure) - This DTC indicates that the Pneumatic Test has failed to
complete, possibly due to mechanical or electrical failure of the air suspension system. DTCs C1990
and/or C1991 will also set with this DTC.

Air leak(s)
Air tube restricted or leak(s)
Air tube(s)
Mounting bracket(s)
Air compressor drier
Air spring solenoid valve(s)
Height sensor(s)
Air compressor
Air spring(s)
VDM
PINPOINT TEST C: VEHICLE RAISES AND/OR LOWERS TOO SLOWLY OR UNEVEN VEHICLE HEIGHT
NOTE: It may be necessary to vent air from the front air suspension air springs during this pinpoint test.

C1 CHECK THE AIR SUSPENSION HEIGHT
SENSORS
Yes
Inspect the air suspension height sensors for GO to C2 .
correct installation.
Inspect the air suspension height sensor No
mounting brackets damage. REPAIR as necessary. If one or both height
While listening for air leaks, verify that all air sensor assemblies are installed or repaired, both
tubes are fully seated. height sensors must be calibrated. RESET the
Are the air suspension height sensors, vehicle ride height. REFER to Ride Height
mounting brackets and air tubes OK? Adjustments in this section. CLEAR the DTCs.
C2 CHECK THE AIR SUSPENSION HEIGHT
SENSOR VOLTAGE PIDs
Yes
Disable the air suspension system. Refer to CONNECT the sensor arm linkages to the height
Air Suspension System Disable/Enable in this sensors. GO to C3 .
section.
Disconnect the sensor arm linkage from both No
rear air suspension height sensors. INSTALL a new height sensor(s) and
Connect the scan tool. CALIBRATE both height sensors. REFER to
PINPOINT TEST C: VEHICLE RAISES AND/OR LOWERS TOO SLOWLY OR UNEVEN VEHICLE
1877HEIGHT
Ignition ON. Suspension Height Sensor in this section.

Enter the following diagnostic mode on the CLEAR the DTCs. RESET the vehicle ride
scan tool: DataLogger VDM . height. REFER to Ride Height Adjustments in
NOTE: The voltage will increase as the this section. REPEAT the self-test.
suspension is compressed.
Slowly move the height sensors through their
full range of travel up and down while
monitoring the following PIDs:
(LR_HEIGHT)
(RR_HEIGHT)
Do the voltages vary from approximately
0.50 volt and 4.50 volts?
C3 VERIFY THAT THE REAR OF THE
VEHICLE CAN BE RAISED
Yes
Toggle the LR and RR air spring solenoid GO to C4 .
(LR_SOL and RR_SOL) active commands
ON. Toggle the air compressor No
(COMPRESSR) active command ON. GO to C5 .
While monitoring both height sensor voltage
PIDs, allow the vehicle to raise for 30 to 45
seconds.
Toggle the VDM active commands OFF.
Does the rear of the vehicle raise normally
and hold the new height?
C4 VERIFY THAT THE REAR OF THE
VEHICLE CAN BE LOWERED
Yes
Toggle the LR and RR air spring solenoid CARRY OUT the Pneumatic Test and VERIFY
(LR_SOL and RR_SOL) active commands system operation.
ON.
Toggle the vent solenoid (AsVent) active No
command ON. GO to C7 .
NOTE: Allow the rear to lower for 30
seconds.
Toggle all active commands OFF.
Does the rear lower normally?
C5 CHECK OPERATION OF THE AIR
COMPRESSOR
Yes
NOTICE: The Vehicle Dynamics Module TOGGLE the COMPRESSR active command
(VDM) limits the air compressor run time. OFF. GO to C6 .
If the air compressor overheats, it will not
restart until it cools down. The ignition No
switch must be in the OFF position to allow TOGGLE the COMPRESSR active command
the compressor thermal switch to cool. OFF. GO to Pinpoint Test J .
Toggle the air compressor (COMPRESSR)

active command ON.
Does the air compressor run (slight buzzing
noise from RF corner of vehicle)?
1878HEIGHT
C6 CHECK THE AIR COMPRESSOR

PRESSURE OUTPUT
Yes
NOTICE: The Vehicle Dynamics Module GO to C8 .
(VDM) limits the air compressor run time.
If the air compressor overheats, it will not No
restart until it cools down. The ignition INSTALL a new air suspension compressor.
switch must be in the OFF position to allow REFER to Air Suspension Compressor in this
the compressor thermal switch to cool. section. CARRY OUT the Pneumatic Test.
VERIFY system operation.
NOTE: If fluid is present when disconnecting
an air tube, clear the air tubes. Refer to Air
Line Fluid Purge procedure in this section.
Check the compressor air drier for water or
the front air spring for oil.
Disconnect the air tube at the air compressor

drier.
Connect an air pressure gauge (1,723 kPa
[250 psi] maximum reading) with common
fittings to the air drier.
NOTE: The vehicle will lower quickly.
NOTE: When toggling the compressor ON,
the vent solenoid will open as well. To
prevent the vent solenoid from opening during
this test, first toggle a single spring solenoid
ON, then toggle the compressor ON.
Toggle the LR spring solenoid (LR_SOL)
active command ON.
Toggle the air compressor (COMPRESSR)
active command ON.
Operate the air compressor for 30 seconds
then toggle the COMPRESSR active
command OFF.
Did the compressor produce 1,034 kPa (150
psi) within 30 seconds?
C7 CHECK THE PNEUMATIC SYSTEM -
VENT THE AIR SPRINGS
Yes
NOTE: If fluid is present when disconnecting TOGGLE the LR_SOL active command OFF.
the air tube, clear the air tubes. Refer to Air GO to C9 .
Line Fluid Purge in this section. Check the air
compressor drier for water or the air No
compressor for oil contamination. TOGGLE the LR_SOL active command OFF.
NOTE: The rear springs must be partially CONNECT the air tube to the air compressor
inflated in order to carry out this test. Add air drier. GO to C8 .
as necessary.
Disconnect the air tube at the air compressor

drier.
Toggle the LR air spring solenoid (LR_SOL)
active command ON. This will activate both
the LR and RR air spring solenoids.
1879HEIGHT
Does the air vent from the air compressor

drier air tube?
C8 CHECK THE PNEUMATIC SYSTEM - AIR
TUBE
Yes
NOTE: If fluid is present when disconnecting REPAIR or INSTALL a new air tube. CLEAR
the air tube, clear the air tubes. Refer to Air the DTC. REPEAT the self-test.
Line Fluid Purge in this section. Check the air
compressor drier for water or the air No
compressor for oil contamination. GO to C11 .
Disconnect the suspected rear air spring

solenoid air tube.
Connect the vacuum tester to the air tube and
try to pull a vacuum.
Can a vacuum be developed?
C9 CHECK THE VENT SOLENOID
OPERATION
Yes
Disconnect the air tube at the drier. INSTALL a new VDM . REFER to Vehicle
Connect the vacuum tester to the drier and try Dynamics Module (VDM) in this section.
to pull a vacuum. CLEAR the DTCs. REPEAT the self-test.
Toggle the vent solenoid (AsVent) active
command ON. No
Try to pull a vacuum again. If a vacuum can be developed with the vent
Can a vacuum be developed with the As solenoid OFF, GO to C10 .
Vent active command OFF and no vacuum
developed with the As Vent active If a vacuum cannot be developed with the vent
command ON? solenoid OFF, INSTALL a new air compressor.
REFER to Air Suspension Compressor in this
section.
C10 CHECK THE AIR TUBE AND
CONNECTIONS
Yes
Check the air tube and connections between INSTALL a new air compressor. REFER to Air
the vacuum tester and the air compressor. Suspension Compressor in this section. CLEAR
Are the air tube and connections OK? the DTC. REPEAT the self-test.
No
REPAIR the air tube. GO to C9 .
C11 CHECK THE SPRING SOLENOID VALVE
Yes
NOTE: The air springs must be inflated for TOGGLE the active commands OFF. INSTALL
this test. a new VDM . REFER to Vehicle Dynamics
Module (VDM) in this section.
Disconnect the air tube at the air spring
solenoids. No
Toggle the LR and RR air spring solenoid TOGGLE the active commands OFF. INSTALL
(LR_SOL and RR_SOL) active commands a new air spring solenoid. REFER to Air Spring
ON. Solenoid Valve in this section.
Does air vent from the solenoids?
1880HEIGHT
Pinpoint Test D: DTC C1770
Normal Operation
The Vehicle Dynamics Module (VDM) will command the air suspension system vent solenoid ON or OFF
when certain conditions are met. The VDM supplies voltage to the vent solenoid through circuit CCL14
(BN/VT), which activates the vent solenoid and vents the air suspension system. The vent solenoid is
grounded through circuit GD123 (BK/GY).
The vent solenoid is part of the air suspension compressor, if a new vent solenoid is needed, an air suspension
compressor must be installed.
DTC C1770 (Air Suspension Vent Solenoid Output Circuit Failure) - With the ignition in the RUN
position and during a deflate (vent) activity, if the VDM detects an open, a short to voltage or a short
to ground on the vent solenoid output circuit, DTC C1770 will be set.

Air suspenon compressor
VDM
PINPOINT TEST D: DTC C1770

D1 CHECK THE VENT SOLENOID
PIDs
Yes
Connect the scan tool. For a short to ground, GO to D3 .
Ignition ON.
Enter the following diagnostic mode For a short to voltage, GO to D4 .
on the scan tool: DataLogger VDM .
Monitor the following VDM PIDs: For an open circuit, GO to D2 .
Vent solenoid output open
circuit (VSOL_RLY_OC) No
Vent solenoid output short to The condition is not present at this time. CLEAR the
battery (VSOL_RLY_STB) DTCs. REPEAT the self-test.
Vent solenoid output short to
ground (VSOL_RLY_STG)
Do any of the PIDs display "Yes"?
D2 CHECK CIRCUIT GD123 (BK/GY)
FOR AN OPEN

Ignition OFF. Yes

Disable the air suspension system. INSPECT the air suspension compressor C1179 for
Refer to Air Suspension System corrosion and damage.
Disable/Enable in this section.
Disconnect: Air Suspension If the connector is corroded or damaged, REPAIR as
Compressor C1179. necessary.
Measure the resistance between air
compressor assembly C1179-3, If the connector is OK, GO to D5 .
circuit GD123 (BK/GY), harness side
and ground. No
REPAIR circuit GD123 (BK/GY). CLEAR the DTCs.

D3 CHECK THE VENT CONTROL
Yes
Disable the air suspension system. GO to D5 .
Refer to Air Suspension System
Disable/Enable in this section. No
Ignition OFF. REPAIR circuit CCL14 (BN/VT).
Disconnect: Air Suspension
Compressor C1179. CLEAR the DTCs. REPEAT the self-test.
Disconnect: VDM C2131a.
Disable the air suspension system.
Refer to Air Suspension System
Measure the resistance between air
compressor C1179-4, circuit CCL14
(BN/VT), harness side and ground.
Is the resistance greater than

10,000 ohms?
D4 CHECK THE VENT CONTROL
PINPOINT TEST D: DTC C1770 1882

Disable the air suspension system. Yes

Refer to Air Suspension System REPAIR circuit CCL14 (BN/VT). CLEAR the DTCs.
Disable/Enable in this section. REPEAT the self-test.
Ignition OFF.
Disconnect: Air Suspension No
Compressor C1179. GO to D6 .
Ignition ON.
Measure the voltage between air
compressor C1179-4 circuit CCL14
(BN/VT) harness side and ground.

D5 CHECK THE VENT SOLENOID
FOR AN OPEN OR A SHORT
Yes
Measure the resistance between air GO to D6 .
compressor C1179 pin-4, component
side and C1179 pin-3, component No
side. INSTALL a new air compressor. REFER to Air
Is the resistance between 17 and 22 Suspension Compressor in this section. CLEAR the
ohms? DTCs. REPEAT the self-test.
D6 CHECK THE VDM CONNECTOR
Yes
Ignition OFF. INSTALL a new VDM . REFER to Vehicle Dynamics
Check VDM C2131a for: Module (VDM) in this section. CLEAR the DTCs.
corrosion. REPEAT the self-test. Both height sensors must be
pushed-out pins. calibrated. RESET the vehicle ride height. REFER to
spread terminals. Ride Height Adjustments in this section.
Connect: VDM C2131a.
Make sure the connector is seated No
correctly then operate the system and The system is operating correctly at this time. Concern
verify the concern is still present. may have been caused by a loose or corroded connector.
Pinpoint Test E: DTCs C1790 (LR) and C1795 (RR)
Normal Operation
The Vehicle Dynamics Module (VDM) will command the air spring solenoid(s) ON or OFF when certain
conditions are met. The left solenoid receives voltage from the VDM along circuit CCL05 (WH/BN), the right
solenoid receives voltage from the VDM along circuit CCL07 (YE/GY). The 2 solenoids share a common

ground along circuit GD120 (BK/GN).
DTC C1790 (LR Air Suspension Air Spring Solenoid Output Circuit Failure) - With the ignition in
the RUN position and during a deflate (vent) or inflate (pump) activity, if the VDM detects an open, a
short to voltage or a short to ground on the LR air spring solenoid output circuit, DTC C1790 will be
set.
DTC C1795 (RR Air Suspension Air Spring Solenoid Output Circuit Failure) - With the ignition in
the RUN position and during a deflate (vent) or inflate (pump) activity, if the VDM detects an open, a
short to voltage or a short to ground on the RR air spring solenoid output circuit, DTC C1795 will be
set.
Thinpoint test is intended to diagnose the following:

Air spring solenoid(s)
VDM
PINPOINT TEST E: DTCs C1790 (LR) AND C1795 (RR)

E1 CHECK THE AIR SPRING SOLENOID PID
Yes
Ignition ON.
Enter the following diagnostic mode on the scan tool: No
DataLogger VDM . GO to E2 .
Monitor the following VDM PIDs:
Left rear solenoid driver short to ground
(LSOL_DR_STG)
Right rear solenoid driver short to ground
(RSOL_DR_STG)
Do the PIDs indicate a short to ground?
E2 CHECK THE AIR SPRING SOLENOID CONNECTOR(S)
Yes
Disable the air suspension system. Refer to Air Suspension GO to E3 .
System Disable/Enable in this section.
Using the DTCs obtained after running the VDM self-test, No
determine which air spring solenoid is causing the concern. REPAIR the connector(s) as
Ignition OFF. necessary. CLEAR the DTCs.
Disconnect: Suspect Air Spring Solenoid Connector. REPEAT the self-test.
Inspect the pins and terminals of the air spring solenoid
connector(s) for corrosion, damage, pushed-out pins, spread
terminals, moisture or other damage.
Is the air spring solenoid connector(s) OK?
E3 CHECK THE AIR SPRING SOLENOID CONTROL
CIRCUIT(S) FOR A SHORT TO GROUND
PINPOINT TEST E: DTCs C1790 (LR) AND C1795 (RR) 1884

Disable the air suspension system. Refer to Air Suspension Yes

System Disable/Enable in this section. GO to E4 .
Ignition OFF.
Disconnect: VDM C2131b. No
Disconnect: Air Spring Solenoids C4044 LR and C4045 RR. REPAIR the affected circuit(s).
Measure the resistance between C4044-1, circuit CCL05
(WH/BN), harness side and ground. CLEAR the DTCs. REPEAT the
self-test.
Measure the resistance between C4045-1, circuit CCL07

(YE/GY), harness side and ground.

E4 CHECK THE AIR SPRING SOLENOID CONTROL
CIRCUIT FOR SHORT TO VOLTAGE
Yes
Disable the air suspension system. Refer to Air Suspension REPAIR the affected circuit(s).
System Disable/Enable in this section. CLEAR the DTCs. REPEAT the
Ignition OFF. self-test.
Disconnect: Air Spring Solenoids C4044 LR and C4045 RR. No
For the LR air spring solenoid, measure the voltage
between C4044-1, circuit CCL05 (WH/BN), harness side
and ground.
For the RR air spring solenoid, measure the voltage

between C4045-1, circuit CCL07 (YE/GY), harness side and
ground.


E5 CHECK CIRCUIT GD120 (BK/GN) FOR AN OPEN
Yes
For the RR air spring solenoid , measure the resistance
between C4045-2, circuit GD120 (BK/GN), harness side and No
ground. REPAIR circuit GD120 (BK/GN).
self-test.
For the LR air spring solenoid , measure the resistance

between C4044-2, circuit GD120 (BK/GN), harness side and
ground.

E6 CHECK THE AIR SPRING SOLENOID COIL(S) FOR AN
OPEN
Yes
For the RR air spring solenoid , measure the resistance GO to E7 .
between air spring solenoid C4045 pin-1, component side
and air spring solenoid C4045 pin-2, component side. No
For the LR air spring solenoid , measure the resistance INSTALL a new air spring
between air spring solenoid C4044 pin-1, component side solenoid(s). REFER to Air Spring
and air spring solenoid C4044 pin-2, component side. Solenoid Valve in this section.
Is the resistance between 15 and 19 ohms (if the solenoid CLEAR the DTCs. REPEAT the
is very hot, the resistance may be as high as 22 ohms)? self-test.
E7 CHECK THE VDM CONNECTOR
Yes
Check the VDM connector for: INSTALL a new VDM . REFER

corrosion. to Vehicle Dynamics Module

pushed-out pins. (VDM) in this section. CLEAR the
spread terminals. DTCs. REPEAT the self-test.
Connect: VDM C2131b.
Make sure the connector is seated correctly then enable the No
air suspension system, operate the system and verify the The system is operating correctly
concern is still present. at this time. Concern may have
Is the concern still present? been caused by a loose or corroded
connector.
Pinpoint Test F: DTCs C1893 (LR) and C1885 (RR)
Normal Operation
sensor sends the suspension height voltage back to the VDM along circuit VCL12 (WH/VT). The LR sensor
sends the suspension height voltage back to the module along circuit VCL13 (BN/BU). The VDM monitors
the 2 height sensors and makes adjustments to the rear suspension based on sensor input.
DTC C1893 (Air Suspension LR Height Sensor Circuit Failure) - With the ignition in the RUN
position, if the height sensor is reading less than 0.5 volt or more than 4.5 volts, DTC C1893 will be
set.
DTC C1885 (Air Suspension RR Height Sensor Circuit Failure) - With the ignition in the RUN
position, if the height sensor is reading less than 0.5 volt or more than 4.5 volts, DTC C1885 will be
set.

Height sensor(s)
VDM
PINPOINT TEST F: DTCs C1893 (LR) AND C1885 (RR)

F1 CHECK THE AIR SUSPENSION HEIGHT
SENSOR VOLTAGE PIDs
Yes
Disable the air suspension system. Refer to Air INSPECT the height sensor electrical
Suspension System Disable/Enable in this section. connector(s) for corrosion and damage,
Connect the scan tool. REPAIR as necessary. CLEAR the DTCs.
Ignition ON. REPEAT the self-test.
tool: DataLogger VDM . No
Disconnect the sensor arm linkage from both rear CONNECT the sensor arm linkages to the
air suspension height sensors. air suspension height sensors. GO to F2 .

NOTE: The voltage will increase as the suspension

is compressed.
Slowly move the height sensors through their full
range of travel up and down while monitoring the
following PIDs:
(LR_HEIGHT)
(RR_HEIGHT)
Do the voltages vary from approximately 0.50
volt and 4.50 volts?
F2 CHECK CIRCUIT VCL12 (VT/OG) FOR
VOLTAGE
Yes
Disconnect: Suspect Height Sensor.
Ignition ON. No
For the LR height sensor , measure the voltage GO to Pinpoint Test B .
between LR height sensor C4092-3, circuit VCL12
For the RR height sensor , measure the voltage

between RR height sensor C4093-3, circuit VCL12

F3 CHECK CIRCUITS VCL13 (BN/BU) AND VCL12
(WH/VT) FOR AN OPEN
Yes
For the LR height sensor , measure the resistance No
between VDM C2131b-6, circuit VCL13 (BN/BU), REPAIR the affected circuit(s). CLEAR the
harness side and LR height sensor C4092-2, circuit DTCs. REPEAT the self-test.
VCL13 (BN/BU), harness side.
PINPOINT TEST F: DTCs C1893 (LR) AND C1885 (RR) 1888

For the RR height sensor , measure the resistance

between VDM C2131b-1, circuit VCL12
(WH/VT), harness side and RR height sensor
C4093-2, circuit VCL12 (WH/VT), harness side.

(WH/VT) FOR A SHORT TO GROUND
Yes
For the LR height sensor , measure the resistance GO to F5 .
between LR height sensor C4092-2, circuit VCL13
(BN/BU), harness side and ground. No

between RR height sensor C4093-2, circuit VCL12
(WH/VT), harness side and ground.

(WH/VT) FOR A SHORT TO VOLTAGE

Ignition ON. Yes

For the LR height sensor , measure the voltage REPAIR the affected circuit(s). CLEAR the
between LR height sensor C4092-2, circuit VCL13 DTCs. REPEAT the self-test.
For the RR height sensor , measure the voltage No
between RR height sensor C4093-2, circuit VCL12 GO to F6 .
(WH/VT), harness side and ground.

F6 CHECK FOR SIGNAL RETURN SHORTED TO
VOLTAGE
Yes
For the LR height sensor , measure the voltage GO to Pinpoint Test B .
between LR height sensor C4093-1, circuit RCL12
(GN/WH), harness side and ground. No
GO to F7 .
For the RR height sensor , measure the voltage

between RR height sensor C4092-1, circuit RCL12
(GN/WH), harness side and ground.

F7 CHECK CIRCUIT RCL12 (GN/WH) FOR AN
OPEN

Ignition OFF. Yes

For the LR height sensor , measure the resistance GO to F8 .
between VDM C2131b-5, circuit RCL12
(GN/WH), harness side and LR height sensor No
C4092-1, circuit RCL12 (GN/WH), harness side. REPAIR circuit VCL12 (WH/VT). CLEAR

between VDM C2131b-5, circuit VCL12
(WH/VT), harness side and RR height sensor
C4093-2, circuit VCL12 (WH/VT), harness side.

F8 VERIFY HEIGHT SENSOR(S) OUTPUT
VOLTAGE
Yes
Connect: VDM C2131b. GO to F9 .
Connect: RH Height Sensor C4093 and LH Height
Sensor C4092. No
Disable the air suspension system. Refer to Air INSTALL a new height sensor(s) and
Suspension System Disable/Enable in this section. CALIBRATE both height sensors. REFER
Back probe RR height sensor C4093-2, circuit to Suspension Height Sensor in this section,
VCL12 (WH/VT) and LR height sensor C4092-2, CLEAR the DTCs. REPEAT the self-test.
circuit VCL12 (WH/VT).
Is the voltage reading the same as the sensor PID
reading?
F9 CHECK THE VDM CONNECTOR
Yes
Disconnect: VDM C2131b. INSTALL a new VDM . REFER to Vehicle
Check VDM C2131b for: Dynamics Module (VDM) in this section.
corrosion. CLEAR the DTCs. REPEAT the self-test.
pushed-out pins.
Connect: VDM C2131b. The system is operating correctly at this
Make sure the connector is seated correctly then time. Concern may have been caused by a
enable the air suspension system, operate the loose or corroded connector.
system and verify the concern is still present.

Pinpoint Test G: The Air Compressor Runs Continuously With the Ignition Switch in the OFF Position
and No DTC is Set
Normal Operation
With the air suspension system activated and the ignition switch in the ON position, the Vehicle Dynamics
Module (VDM) uses input from the 2 suspension height sensors to determine if vehicle payload has changed
enough to warrant the adjustment of the rear suspension. If an adjustment is necessary, the VDM will open the
air spring solenoids and activate the air compressor to inflate the air springs and raise the rear suspension. To
deflate the air springs and lower the rear suspension, the VDM will open the air spring solenoids and activate
the vent solenoid.
With the air suspension system deactivated and the ignition switch in the OFF position, the VDM will ignore
height sensor input and not adjust the rear suspension. When only the ignition switch is placed in the OFF
position, the VDM will remain powered for approximately 40 minutes to allow the system to adjust the rear
suspension due to changes in vehicle payload. The system can deflate (vent) at any time during these 40
minutes and will only inflate (pump) once during the last 30 seconds, if necessary. Once the 40 minutes has
elapsed, the VDM will depower and ignore any height sensor input until the ignition switch is placed in the
ON position.
To activate the air compressor, the VDM supplies voltage to the air compressor relay along circuit CCL01
(WH/VT). This voltage passes through the coil side of the relay and to ground along circuit GD123 (BK/GY),
which energizes the relay. The switch side of the relay receives fused battery voltage from Battery Junction
Box (BJB) fuse 19 (60A) along circuit SBB19 (BU/RD). When the relay is energized, the switch side closes
and this fused battery voltage is sent to the air compressor along circuit CCL08 (BU/BN). The voltage passes
through the air compressor and to ground along circuit GD123 (BK/GY), which activates the air compressor.

Air compressor relay
VDM
PINPOINT TEST G: THE AIR COMPRESSOR RUNS CONTINUOUSLY WITH THE IGNITION SWITCH IN THE OFF
POSITION

G1 CHECK THE RELAY CONTROL CIRCUIT FOR A
SHORT TO VOLTAGE
Yes
Disable the air suspension system. Refer to Air Suspension REPAIR circuit CCL01 (WH/VT).
System Disable/Enable in this section. CLEAR the DTCs. REPEAT the
Remove the air compressor relay. No
Measure the voltage between air compressor relay, circuit
CCL01 (WH/VT), harness side and ground.


G2 CHECK FOR MODULE ACTIVITY
Yes
NOTE: If the key has been off for 39 minutes and 39 GO to G3 .
seconds, the compressor is permitted to run once for a
maximum of 30 seconds. No
The system is OK. INFORM the
Ignition OFF. owner of system operations.
Connect: Air Compressor Relay.
Enable the air suspension. Refer to Air Suspension System
Ignition ON.
Ignition OFF.
Verify the air compressor still cycles for a maximum of 30
seconds after the ignition is turned OFF.
Does the air compressor still cycle for greater than 30
seconds after the ignition is turned OFF?
G3 CHECK THE VDM
Yes
Disable the air suspension system. Refer to Air Suspension GO to G4 .
System Disable/Enable in this section.
Disconnect: VDM C2131a. No
Disconnect: VDM C2131b. INSTALL a new VDM . REFER to
Does the air compressor still cycle? Vehicle Dynamics Module (VDM)
in this section. REPEAT the
self-test.
G4 CHECK CIRCUIT CCL08 (BU/BN) FOR A SHORT TO
VOLTAGE
Yes
Disconnect: Air Compressor Relay. REPAIR circuit CCL08 (BU/BN).
Does the air compressor still cycle? TEST the system for normal
operation.
No
INSTALL a new air compressor
relay. TEST the system for normal
PINPOINT TEST G: THE AIR COMPRESSOR RUNS CONTINUOUSLY WITH THE IGNITION 1893
SWITCH IN
operation.
Pinpoint Test H: The Air Suspension System is Inoperative Without DTCs and with the Vehicle at Rest
Normal Operation
The scan tool is used to communicate with the Vehicle Dynamics Module (VDM) and run the self-test. The
VDM is supplied fused battery voltage through Battery Junction Box (BJB) fuse 48 (30A) along circuit
SBB48 (VT/RD), and fused ignition circuit through BJB fuse 53 (10A) along circuit CBB53 (GY/BN). A
ground path is provided for the module along circuit GD120 (BK/GN). The VDM communicates with the
other modules along the High Speed Controller Area Network (HS-CAN). The VDM must receive inputs
from several different components before it will allow the vehicle dynamic suspension system to operate.

Fuse(s)
Door switch is indicating door ajar status
Vehicle speed signal
System is not enabled
VDM
PINPOINT TEST H: THE AIR SUSPENSION SYSTEM IS INOPERATIVE WITHOUT DTCs AND WITH THE VEHICLE
AT REST
NOTE: If the vehicle has been sitting with the key in the run position, it may be necessary to open and close
the driver side door. This will enable the system to carry out the pump or vent functions quicker.

H1 VERIFY THAT THE SYSTEM IS
ENABLED
Yes
Verify that the air suspension GO to H2 .
system is enabled. Refer to Air
Suspension System Disable/Enable No
in this section. ENABLE the air suspension system. REFER to Air
Is the air suspension system Suspension System Disable/Enable in this section.
enabled?
H2 CHECK THE VDM IGNITION
SWITCH (IGN_RUN) PID
Yes
Connect the scan tool. GO to H3 .
Ignition ON.
Enter the following diagnostic mode No
on the scan tool: DataLogger VDM VERIFY BJB fuse 53 (10A) is OK. If OK, REPAIR circuit
. CBB65 (WH/OG). If not OK, REFER to the Wiring
While cycling the ignition key from Diagrams manual to identify the possible causes of the
ON to OFF and then back to ON, circuit short. TEST the system for normal operation.
monitor the IGN_RUN PID.
Does the PID display NO with the
key in the OFF position and YES
with the key in the ON position?

H3 CHECK THE VDM DRIVER

DOOR AJAR SWITCH (D_DR_SW) PID
Yes
Monitor VDM door ajar PID.
Close all the doors, liftgate, liftgate No
glass and power running boards. REFER to Section 418-01 to diagnose the High Speed
While monitoring the D_DR_SW Controller Area Network (HS-CAN) concern.
PID, open and close the driver door.
Does the PID change from
CLOSED to OPEN?
H4 CHECK THE VDM VSS PID
Yes
Monitor the VSS PID. GO to H5 .
Test drive the vehicle at different
speeds. No
Does the VSS PID match the REFER to Section 418-01 to diagnose the HS-CAN
speedometer within 8 km/h (5 concern.
mph)?
H5 CHECK THE VDM
CONNECTORS
Yes
Disconnect: VDM C2131b. No
Check the VDM connectors for: The system is operating correctly at this time. Concern may
corrosion. have been caused by a loose or corroded connector.
pushed-out pins.
spread terminals.
Connect: VDM C2131b.
Make sure the connectors are seated
correctly then enable the air
suspension system, operate the
system and verify the concern is still
present.
H6 VERIFY THE SYSTEMS
OPERATION
Yes
Using the scan tool, carry out the RECORD the DTCs and REFER to the Vehicle Dynamics
Pneumatic Test. Module (VDM) DTC Chart.
Does running the Pneumatic Test
generate any DTCs? No
The system is operating correctly at this time. Concern may
have been caused by a loose or corroded connector.
Pinpoint Test I: Excessive Air Compressor Noise
PINPOINT TEST H: THE AIR SUSPENSION SYSTEM IS INOPERATIVE WITHOUT DTCs AND
1895
WITH THE
Normal Operation
The air compressor is isolated from the rest of the vehicle and other components by 3 rubber isolators and a
bracket. The bracket is mounted to the vehicle using 3 rubber isolators with metal inserts. The air compressor
should not be in contact with the vehicle or other components.

Compressor bracket
Bracket isolators
Compressor mounts
Component routing
Wire harness routing
PINPOINT TEST I: EXCESSIVE AIR COMPRESSOR NOISE

I1 CHECK FOR THE AIR COMPRESSOR
AND/OR THE AIR COMPRESSOR WIRING
CONTACTING OTHER COMPONENTS
Yes
Check the air compressor wiring to see if it is REMOVE the air compressor assembly,
contacting other components inside the engine REFER to Air Suspension Compressor in this
compartment at any place other than the section. ADJUST the air compressor wiring
mounting points. harness so that it does not contact the
Check for anything contacting the air compressor motor or FASTEN/REMOVE
compressor (other wire harnesses, air tubes, objects so they no longer contact the air
hoses, loose fasteners, stones or other foreign compressor assembly.
material).
Check for any contact between the wire harness INSTALL the air compressor assembly,
and other compressor components. REFER to Air Suspension Compressor in this
Is any portion of the wire harness contacting section. TEST the system for normal operation.
the compressor motor components or is
anything contacting the compressor No
assembly other than the mounts? GO to I2 .
I2 CHECK FOR A BENT AIR COMPRESSOR
BRACKET
Yes
Check the air compressor bracket for any INSTALL a new air compressor assembly or
damage/bends that may contact other REPAIR other components as necessary.
components within the engine compartment. REFER to Air Suspension Compressor in this
Check the bracket rubber isolators and inserts section. TEST the system for normal operation.
for any excessive wear or damage.
Is the air compressor bracket making contact No
with other components or are the bracket GO to I3 .
isolators damaged?
I3 CHECK THE AIR COMPRESSOR MOUNTS
FOR DAMAGE
Yes
Check the air compressor mounts for signs of INSTALL a new air compressor assembly.
cracks or tearing away from the inner sleeve. REFER to Air Suspension Compressor in this
Is damage present in the mounts? section. TEST the system for normal operation.

No
GO to I4 .
I4 CHECK THE AIR COMPRESSOR FOR
NOISE
Yes
NOTICE: Do not run the air compressor for TOGGLE the COMPRESSR active command
more than 3 minutes. The air compressor OFF. INSTALL a new air compressor. REFER
can overheat and stop operating due to an to Air Suspension Compressor in this section.
internal temperature sensitive thermal TEST the system for normal operation.
breaker. The Vehicle Dynamics Module
(VDM) will limit run time to protect the air No
compressor. When DTC C1964 is present, TOGGLE the COMPRESSR active command
the compressor will not operate for OFF. RECHECK the mountings and bracket for
approximately 10 minutes. damage. If damaged, INSTALL a new air
compressor bracket. REFER to Air Suspension
Remove the air compressor assembly, but leave Compressor in this section. TEST the system
it connected electrically. Refer to Air for normal operation.
Suspension Compressor in this section.
Ignition ON.
tool: DataLogger VDM .
Toggle the VDM air compressor
(COMPRESSR) active command ON.
Is the air compressor exhibiting any unusual
noise?
Pinpoint Test J: The Air Compressor is Inoperative
Normal Operation
The Vehicle Dynamics Module (VDM) will activate the air compressor once certain conditions are met. To
activate the air compressor, the VDM supplies voltage to the air compressor relay along circuit CCL01
(WH/VT). This voltage passes through the coil side of the relay and to ground along GD123 (BK/GY), which
energizes the relay. The switch side of the relay receives fused battery voltage from Battery Junction Box
(BJB) fuse 19 (60A) along circuit SBB19 (BU/RD). When the relay is energized, the switch side closes and
this fused battery voltage is sent to the air compressor along circuit CCL08 (BU/BN). The voltage passes
through the air compressor and to ground along circuit GD123 (BK/GY), which activates the air compressor.
To protect the air compressor from damage due to excessive run time and heat build up, the air compressor
assembly contains a temperature sensitive, thermal circuit breaker and the VDM contains software to monitor
how long the compressor has been running. The circuit breaker will protect the compressor from damage due
to overheating by disabling the compressor when the compressor reaches a pre-determined temperature
threshold. Once the compressor has been disabled and has had sufficient time to cool (approximately 15
minutes), the circuit breaker will reset and allow the compressor to function. The VDM will also monitor the
amount of time the air compressor runs. Once the run time has reached a pre-determined limit, the VDM will
set DTC C1964 and disable the air compressor until it has had sufficient time to cool down.
DTC C1830 (Air Compressor Relay Circuit Failure) - With the ignition in the RUN position and ring
a deflate (vent) or inflate (pump) event, if the VDM detects an open, a short to voltage or a short to
PINPOINT TEST I: EXCESSIVE AIR COMPRESSOR NOISE 1897

ground on circuit CCL01 (WH/VT), DTC C1830 will be set.
DTC C1964 (Compressor Run Time Exceeded) - With the ignition in the RUN position and during an
inflate (pump) event, if the air compressor exceeds a pre-determined run time limit, DTC C1964 will
be set.

Fuse(s)
Air compressor relay
Air compressor
VDM
PINPOINT TEST J: THE AIR COMPRESSOR IS INOPERATIVE

J1 ISOLATE THE AIR COMPRESSOR RELAY
Yes
Carry out the mini-ISO relay component test. GO to J2 .

testing. REPAIR or INSTALL a new air
Inspect the rel and socket for corrosion, pushed-out compressor relay as necessary. CLEAR
pins and spread terminals. the DTC. REPEAT the self-test.
Does the air compressor relay pass the test and are
the relay and socket OK?
J2 CHECK VDM DTCs
Yes
Review the VDM DTCs retrieved during Inspection If only DTC C1964 is present, ALLOW
and Verification. the air compressor a minimum of 10
Are any VDM DTCs present? minutes to cool. CLEAR the DTCs.
If DTC C1830 is present, GO to J7 .
If DTC C1726 is present, GO to J3 .
For all other DTCs, GO to the Vehicle

Dynamics Module (VDM) DTC Chart.
No
GO to J3 .
J3 CHECK THE VOLTAGE TO THE AIR
COMPRESSOR RELAY

NOTE: Make sure the battery voltage is greater than Yes

10 volts before testing the compressor relay voltage. GO to J4 .
Ignition OFF. No
Disconnect: Air Compressor Relay. VERIFY BJB fuse 19 (60A) is OK. If
Measure the voltage between air compressor relay, OK, REPAIR circuit SBB19 (BU/RD). If
circuit SBB19 (BU/RD), harness side and ground. not OK, REFER to the Wiring Diagrams
manual to identify the possible causes of
the circuit short. CLEAR the DTCs.

J4 CHECK CIRCUIT CCL08 (BU/BN) FOR AN OPEN
Yes
Disconnect: Air Compressor Assembly C1179. GO to J5 .
Measure the resistance between air compressor relay,
circuit CCL08 (BU/BN), harness side and air No
compressor assembly C1179-2, circuit CCL08 REPAIR circuit CCL08 (BU/BN).
(BU/BN), harness side. CLEAR the DTCs. REPEAT the
self-test.

J5 CHECK THE COMPRESSOR GROUND CIRCUIT
FOR AN OPEN
PINPOINT TEST J: THE AIR COMPRESSOR IS INOPERATIVE 1899

Measure the resistance between air compressor Yes

assembly C1179-1, circuit GD123 (BK/GY), harness GO to J6 .
side and ground.
No
REPAIR circuit GD123 (BK/GY). TEST

J6 ISOLATE THE AIR COMPRESSOR
Yes
NOTICE: Do not run the air compressor for more REMOVE the jumper wire. GO to J11 .
than 3 minutes. The air compressor can overheat
and stop operating due to an internal temperature No
sensitive thermal breaker. REMOVE the jumper wire. INSTALL a
new air compressor. REFER to Air
Connect: Air Compressor Assembly C1179. Suspension Compressor in this section.
Install a fused jumper wire between air compressor CLEAR the DTCs. REPEAT the
relay, circuit SBB19 (BU/RD) and circuit CCL08 self-test.
(BU/BN).
Does the air compressor run?
J7 CHECK THE RELAY CONTROL CIRCUIT FOR A
SHORT TO VOLTAGE
Yes
Disable the air suspension system. Refer to Air REPAIR circuit CCL01 (WH/VT).
Suspension System Disable/Enable in this section. CLEAR the DTCs. REPEAT the
Disconnect: Air Compressor Relay. No
Ignition ON. GO to J8 .
Measure the voltage between air compressor relay,
circuit CCL01 (WH/VT), harness side and ground.


J8 CHECK THE RELAY CONTROL CIRCUIT FOR A
SHORT TO GROUND
Yes
Measure the resistance between air compressor relay,
circuit CCL01 (WH/VT), harness side and ground. No
REPAIR circuit CCL01 (WH/VT).
self-test.

J9 CHECK THE RELAY CONTROL CIRCUIT FOR
AN OPEN
Yes
Measure the resistance between air compressor relay, GO to J10 .
circuit CCL01 (WH/VT) and VDM C2131a-6, circuit
CCL01 (WH/VT), harness side. No
REPAIR circuit CCL01 (WH/VT).
self-test.

J10 CHECK THE AIR COMPRESSOR RELAY
GROUND FOR AN OPEN

Disconnect: Air Compressor Relay. Yes

Measure the resistance between air compressor relay, GO to J11 .
circuit GD123 (BK/GY), harness side and ground.
No
REPAIR circuit GD123 (BK/GY).
self-test.

J11 CHECK THE VDM OPERATION
Yes
Check the VDM connector for: INSTALL a new VDM . REFER to
corrosion. Vehicle Dynamics Module (VDM) in
pushed-out pins. this section. CLEAR the DTCs.
spread terminals. REPEAT the self-test.
Connect: VDM C2131a (if previously disconnected).
Connect: Air Compressor Relay (if previously No
disconnected). The system is operating correctly at this
Make sure the connectors are seated correctly then time. Concern may have been caused by
enable the air suspension system. Refer to Air a loose or corroded connector.
Suspension System Disable/Enable in this section.
Operate the system and verify the concern is still
present.
Pinpoint Test K: DTC C1810
Normal Operation
sensor sends the suspension height voltage back to the VDM along circuit VCL12 (WH/VT). The LR sensor
sends the suspension height voltage back to the module along circuit VCL13 (BN/BU). The VDM monitors
the 2 height sensors and makes adjustments to the rear suspension based on sensor input.
DTC C1810 (Air Suspension Height Sensor Delta Out Of Range) - When performing a self-test, a
ride height adjustment or when the VDM adjusts the ride height through normal operation, if the left
and right calculated ride height value differs by 100 mm (3.93 in) or more, DTC C1810 will be set.

Vehicle lean (air spring leak, asymmetric loading)

Height sensor bracket bent or loose
Height sensor link arm bent, loose or disconnected
Height sensor(s) out of calibration
Air tube restriction
PINPOINT TEST K: DTC C1810

K1 VERIFY THAT DTC C1810 IS PRESENT AND
ACTIVE
Yes
NOTE: The VDM will log DTC C1810 if the left GO to K2 .
and right calculated ride heht value differs by 100
mm (3.93 in) or more. No
GO to K3 .
Ignition ON.
Carry out the Pneumatic Test.
Does DTC C1810 set after carrying out the
Pneumatic Test?
K2 INSPECT THE RH AND LH HEIGHT
SENSORS
Yes
Verify that both height sensor arms are fastened INSTALL new component(s) as necessary,
to the ball studs on the height sensor(s) and lower RESET the vehicle ride height. REFER to
control arm(s). Ride Height Adjustments in this section.
Verify that the height sensor arms are installed REPEAT the self-test.
correctly, and not positioned on backwards.
Inspect for loose or bent height sensor(s) and No
height sensor(s) arms. GO to K3 .
Are any of the height sensor components
damaged?
K3 CHECK THE VEHICLE FOR
ASYMMETRICAL LOADING
Yes
Check for unbalanced or heavy load on one side REPAIR the loading issue and REPEAT the
of the vehicle. self-test.
Is the vehicle heavily loaded on one side
causing the ride height to be incorrect? No
GO to K4 .
K4 CHECK FOR VEHICLE LEANING
Yes
Ignition OFF. GO to K7 .
Position the vehicle on a level surface.
Using the scan tool, carry out the Accurate Trim No
Test. GO to K5 .
Are both the LR and RR ride heights within
specification?
K5 CHECK THE HEIGHT SENSOR OPERATION
DURING PUMP
PINPOINT TEST K: DTC C1810 1903

Using the scan tool, inflate the system to for 30 Yes

seconds and monitor the following PIDs: GO to K6 .
(LR_HEIGHT) No
Right Rear Height Sensor Voltage GO to Pinpoint Test C .
(RR_HEIGHT)
Does the system inflate evenly?
K6 CHECK HEIGHT SENSOR OPERATION
DURING VENT
Yes
Using the scan tool, command the system to vent GO to K7 .
for 20 seconds and monitor the following PIDs:
Left Rear Height Sensor Voltage No
(LR_HEIGHT) GO to Pinpoint Test C .
(RR_HEIGHT)
Does the system deflate evenly?
K7 CHECK THE AIR SPRING(S) FOR LEAKS.
Yes
Inspect both the LR and RR air spring for leaks. REPAIR the leaks, REPEAT the self-test.
Are any leaks present?
No
System operating correctly at this time.
Component Test
Relay
Refer to Wiring Diagrams Cell 149 for component testing.
PINPOINT TEST K: DTC C1810 1904

Air Suspension System Disable/Enable
NOTE: The message center is located on the instrument cluster and displays important information through a
constant monitoring of vehicle systems. Select display features on the message center for a display of status
proceeded by a brief chime. The system will also notify the driver of potential vehicle problems with a display
of system warnings followed by a long indicator chime. The message center is used to disable and enable the
vehicle air suspension system. When the driver elects to disable the air suspension system, the message center
sends a message over the High Speed Controller Area Network (HS-CAN) bus to the air suspension module.
Once the message is received, the air suspension module will take no further action to inflate or deflate the air
springs. The system will default to ON when the ignition key is cycled.
1. Turn the ignition to the ON position, close all doors and clear warnings.
2. Select the SETUP control function on the message center.
3. Select the AIR SUSPENSION function to display the current status of the air suspension system.
4. Press the RESET control to turn the air suspension OFF or ON.
Air Suspension System Disable/Enable 1905

Air Suspension System Disable/Enable 1906

Ride Height Adjustments
Special Tool(s)

NOTICE: The vehicle ride height must be set to the correct dimensions to prevent vehicle damage.
NOTE: Incorrect air suspension ride height can be caused by an air suspension system that is incorrectly set.
NOTE: The Vehicle Dynamics Module (VDM) has a preprogrammed trim height.
1. NOTE: The vehicle must be on a level surface, such as a drive on alignment hoist.
Position the vehicle on a level surface.
2. Using the vehicle message center, verify that the air suspension is in the ON mode. For additional
information, refer to Air Suspension System Disable/Enable in this section.
3. Using the scan tool, run the accurate trim test.
4. Measure the ride height. For additional information, refer to Section 204-00 .
5. If the ride height is not within specification, use the scan tool to vent or fill the air suspension to the
correct dimension.
6. Using the scan tool, save the vehicle trim height for both sensors.
Ride Height Adjustments 1907

Ride Height Adjustments 1908

Air Leaks
1. Apply a soapy water solution to the air lines, air line fittings, air springs, upper spring shock mount
and the air compressor.
2. NOTE: If a leak is detected within the air compressor, install a new compressor. If a leak is detected
in a line, carry out the air line repair procedure using repair kit 5B322. If a leak is detected at an air
spring solenoid valve, remove the solenoid and reseal using repair kit 5B321. For additional
information, refer to Air Spring Solenoid Valve in this section.
Verify the location of air leak(s) and repair or install new components as necessary.
Air Line Repair
1. Cut the line at the damaged area.
2. Trim the sleeve material from both ends of the damaged line.
3. Taper both ends of the tube by shaving or sanding it 3 mm (0.11 in) from the tips.
4. Install the repair filling.
5. NOTE: Check system for leaks.
Inflate the air suspension system. For additional information, refer to Ride Height Adjustments in this
section.
Air Leaks 1909

Air Leaks 1910

Air Line Fluid Purge
1. NOTE: Carry out this procedure if fluid (water and/or oil) is found in the air tube. Purge fluid from
rear air tubes and install new components if affected.
Disconnect the air tube at the air compressor drier.
2. Disconnect the air tube from the air springs.
3. Connect shop air to the disconnected air tube and blow any fluid out.
4. NOTE: When installing the air tubes, make sure the white tube is fully inserted into the fitting for
Reconnect the air tubes at the air springs.
5. Install a new air compressor drier. For additional information, refer to Air Suspension Compressor in
this section.
6. Reconnect the air tube to the air compressor drier.
7. Make sure that all air tube fittings are sealed.
Air Line Fluid Purge 1911

Air Spring Inflation and Deflation
Special Tool(s)

1. Turn the ignition switch to the RUN position.
2. Connect the scan tool to the Data Link Connector (DLC).
3. Select the air suspension control module active command LR_SOL (LR) or RR_SOL (RR) from OFF
to ON.
4. NOTE: When using the air suspension control module active command AS_COMP, do not run the
air compressor for more than 3 minutes to prevent overheating and shutdown. If this occurs, wait for
the system to cool down before resuming the inflation procedure.
Select the air suspension control module active command AsVent to deflate the air springs or
AS_COMP to inflate the air springs.
Air Spring Inflation and Deflation 1912

Air Suspension Compressor

1 W505436 Compressor bolts (3 required)
2 3D002 Compressor air intake hose
3 - Compressor electrical connector (part of 14A464)
4 5319 Compressor and bracket assembly
5 5A897 Air line
6 W520823 Clip nuts (3 required)
1. Remove the inner fender splash shield. For additional information, refer to Section 501-02 .
2. Disconnect the air line from the compressor drier.

Compress the quick connect lock ring inward, then pull the line outward from the air drier.
3. Disconnect the air compressor air intake hose.
4. Disconnect the air compressor electrical connector.
5. Remove the 3 air compressor bracket bolts and remove the air compressor and bracket assembly.
6. NO: When installing the air lines, make sure the white inner air line is fully inserted into the fitting
for correct installation.
NOTE: Make sure that there are no objects trapped under or on the bracket.
Make sure that the air compressor is not in contact with any surrounding components that could cause
vibration noises.
Air Suspension Compressor 1913

NOTE: Make sure that the air compressor moves freely in the rubber isolators.
Make sure that the bracket has no deformations that could cause the 3 rubber isolators to load against
each other.
Air Suspension Compressor 1914

Air Suspension Compressor Drier

1 - O-ring (part of 5346)
2 5346 Compressor drier
3 - Compressor drier screw (part of 5346)
4 3B484 Compressor and bracket assembly
1. Remove the air compressor. For additional information, refer to Air Suspension Compressor in this
section.
2. Remove the compressor drier screw.

3. NOTE: Make sure that the drier O-ring does not remain inside of the compressor assembly.
Rotate the compressor drier 90 degrees counterclockwise to unlock, then remove the air compressor
drier.
4. NOTE: Inspect the compressor drier O-ring for damage and install a new O-ring as necessary.
NOTE: When installing the air lines, make sure the white air line is fully inserted into the fitting for
Air Suspension Compressor Drier 1915

Air Suspension Compressor Drier 1916

Part
1 - Vehicle Dynamics Module (VDM) electrical connector
(part of 14489) (2 required)
2 W707142 VDM bracket nut (2 required)
3 3C142 VDM and bracket assembly
NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges,
damage may result.
1. NOTE: The Vehicle Dynamics Module (VDM) is mounted to the lower left side of the dash above
the parking brake control.
Disconnect the 2 VDM electrical connectors.
2. Remove the VDM bracket nuts and the module.

3. NOTE: The VDM is calibrated with information from the ride height sensors. A new or exchanged
VDM requires that the LH and RH ride height sensors are calibrated and a Pneumatic Test is carried
out. For additional information, refer to Vehicle Dynamic Suspension Calibration Initialize System -
Clear C1990 and C1991 DTCs in this section.
Vehicle Dynamics Module (VDM) 1917

Vehicle Dynamics Module (VDM) 1918

Air Shock Absorber - Rear
Special Tool(s)

Material
Item Specification
XG-4 and/or XL-5
Part
1 5A980 Air shock and spring assembly
2 - Air line (part of 3209)
3 - Air spring solenoid electrical connector (part of
14A464)
4 W712334 Shock upper nut (3 required)
5 5A891 Air spring
6 - Upper mount screws (part of seal kit 5B302)
Air spring upper O-ring seal (part of seal kit 5B302) (2
7 -
required)
Air Shock Absorber - Rear 1919


9 W712134 Shock rod nut
11 - Jounce bumper (part of 18080)
12 - Shock rod upper washer (part of seal kit 5B302)
13 - Shock rod upper O-ring seal (part of seal kit 5B302)
14 - Shock rod lower O-ring seal (part of seal kit 5B302)
15 - Shock rod lower washer (part of seal kit 5B302)
WARNING: Do not apply heat or flame to the shock absorber or strut tube. The shock absorber
and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction may
under pressure. Failure to follow this instruction may result irsonal injury.
NOTICE: Vehicles built prior to 12/03/2007 use a longer air spring and shock absorber than vehicles
built after 12/03/2007. To prevent component damage, it is important to use the correct air spring and
or shock absorber when replacing these parts.
and systems and their failure can result in major service expense. A new part with the same part
number must be used if installation is necessary. Do not use a new part of lesser quality or substitute
design. Torque values must be used as specified during reassembly to make sure of correct retention of
these parts.
1. Using the scan tool, vent the appropriate air spring.
2. Remove the lower arm. For additional information, refer to Section 204-02 .
3. Disconnect the air spring solenoid valve electrical connector.
4. Disconnect the air line at the air valve.

Compress the orange quick connect lock ring, then pull downward on the air supply line.
5. Remove and discard the 3 shock absorber upper nuts.

6. Remove the air shock absorber.
7. NOTE: If the individual spring and/or shock components are not being serviced, continue with Step
14.
NOTE: Use the hex-holding feature to prevent the shock rod from turning while removing the nut.
Remove and discard the shock absorber rod nut.
8. Remove the shock rod upper washer and O-ring seal.

Discard the O-ring seal washer.

9. NOTICE: If the retainer tabs are broken, a new air spring must be installed, or failure of the air
spring may occur.
NOTE: Index-mark the air spring and shock absorber for reference during the installation procedure.
Depress the retainer tabs and remove the air spring.
10. Remove the shock rod lower O-ring seal, washer and jounce bumper.
Discard the seal and washer.
11. Remove and discard the 2 air spring lower O-ring seals.
12. Remove the 2 upper mount screws and the upper mount.
Discard the screws.
To install, tighten the new screws to 4 Nm (35 lb-in).
13. Remove and discard the 2 air spring upper O-ring seals.
14. NOTICE: Use a suitable press to install the upper mount retainer pins. Do not use a hammer or
damage may occur.
NOTICE: When installing the upper and lower shock rod O-ring seals and washers, it is
important to install the washers with the flat face side positioned against the O-ring seals.
Damage to the O-ring seals will occur if the rounded face side of the washers is positioned
against the O-ring seals.
NOTE: Make sure that all seals are clean and free of debris.
NOTE: Apply a thin coat of grease to the new O-ring seals.


Air Spring Solenoid Valve
Special Tool(s)

Material
Item Specification
Dielectric Compound
XG-3-A

1 - Air spring solenoid electrical connector (part of
14A464)
2 - Air line (part of 3C002)
3 - Air spring solenoid valve (part of 3C199)
4 - Solenoid valve O-ring (part of 3C199)
5 - Air spring solenoid clip (part of 3C199)
1. If the air spring solenoid valve is functional, use the scan tool to vent the appropriate air spring(s).
100-02 .
3. Disconnect the air spring solenoid valve electrical connector.
4. Disconnect the air line at the air valve.

Compress the orange quick connect lock ring, then pull downward on the air supply line.
Air Spring Solenoid Valve 1923

5. NOTICE: Remove any dirt or other foreign material from the air spring assembly prior to
removing the air spring solenoid valve from the air spring assembly, or damage to the solenoid
valve and air spring may occur.
Remove the air spring solenoid clip.
6. WARNING: Vent all air pressure from the air suspension system prior to disconnecting or
removing any air suspension components. It is dangerous to remove air suspension components
while under pressure. Failure to follow this instruction may result in serious personal injury.
The air spring solenoid valve has a 2-stage release. Vent the air spring using the following procedure:
1. Carefully rotate the air spring solenoid counterclockwise until it reaches the first stage and
allow the air in the spring to completely vent.
2. Rotate the solenoid counterclockwise to the second stage and remove the solenoid.
7. NOTE: Inspect the air spring O-ring for damage and install a new O-ring as necessary. Lightly
lubricate the solenoid seal area with silicone grease.
NOTE: After installing the solenoid, it is necessary to inflate the air suspension system. For
additional information, refer to Ride Height Adjustments in this section.
NOTE: When installing the air spring solenoid, make sure that the electrical connector is positioned
away from the air spring.
NOTE: When installing the air lines, make sure the air line is fully inserted into the fitting for correct
installation.
Air Spring Solenoid Valve 1924

Suspension Height Sensor
LH Side

1 W506014 Height sensor bolts (4 required)
2 - Height sensor electrical connector (part of 14405)
3 5A967 Height sensor
4 - Sensor arm (part of 5A967)
5 5A945 Height sensor ball stud
6 W711660 Ball stud nut clip
7 W712408 Frame nut clips (2 required)
RH Side

1 W506014 Height sensor bolts (4 required)
2 - Sensor electrical connector (part of 14405)
Suspension Height Sensor 1925

3 5A967 Ride height sensor

4 - Sensor arm (part of 5A967)
5 5A945 Ride height sensor ball stud
6 W711660 Ball stud nut clip
7 W712408 Frame nut clips (2 required)
100-02 .
2. Disconnect the height sensor harness from the sensor bracket.
3. Disconnect the height sensor electrical connector.
4. Disconnect the height sensor arm from the ball stud on the lower control arm.
5. Remove and discard the 2 height sensor bolts.

6. NOTE: The RH and LH height sensor assemblies cannot be used on opposite sides of the vehicle.
7. Calibrate the LH and RH height sensors. For additional information, refer to Ride Height Adjustments
in this section.
RH Side 1926
SECTION 205-00: Driveline System - General 2011 Expedition, Navigator Workshop

Information Manual
Material

Capacity
Motorcraft High Contrast - -
Hypoid Gear Marking
Compound
XG-14
Threadlock and Sealer WSK-M2G351-A5 -
TA-25
Item Specification
Maximum allowable driveshaft runout 1.0 mm (0.040 in)
Maximum axle flange runout 0.15 in)
Minimum Traction-Lok breakaway torque 27 Nm (20 lb-ft)
U-joint operating angle 0.5 degrees-3.0 degrees
RH Side 1927

Information Manual
Driveline System
The driveline is composed of the following:
Front driveshaft
CV joints
Front drive axle
Front axle halfshafts
Rear driveshaft
U-joints and flanges
Flex couplers
Center support bearings
Rear drive axle
Rear axle halfshafts
The source of the drivetrain's power is generated by the engine and delivered to the transmission. The
driveline transfers the engine torque through the driveshaft to the axle.
On Rear Wheel Drive (RWD) vehicles, power is transmitted through the transmission to the
driveshaft and then to the rear axle.
On Four-Wheel Drive (4WD) vehicles, power is transmitted through the transmission and the transfer
case. The transfer case directs the power to the rear driveshaft and then to the rear axle. When
engaged, it also transmits power through the front driveshaft to the front axle.
The rear driveshaft is connected to the output shaft of the transmission or transfer case and to the rear axle.
Thont driveshaft is connected to the transfer case and to the front axle. For Expedition, slip yokes are used to
allow for any changes to the length of the driveshaft. Navigator RWD vehicles use a fixed flange at the
transmission with a flex coupling. Changes in length are self adjusted up in the driveshaft slip mechanism.
The engine torque enters the axle through the drive pinion, which rotates the ring gear. The ring gear is
mounted to the differential case, which contains the gears that transmit power to the rear axle halfshafts or
front halfshafts. These halfshafts rotate the drive wheels.
Axle Identification
The axle ratio may be verified by checking the printed label on the axle housing. If worn or not visible, the
Vehicle Identification Number (VIN) can be typed in the service parts ordering system or the Vehicle
Certification (VC) label may be used to correctly identify the axle and ratio. Refer to the chart below.
Axle Tag Code Ring Gear Axle Ratio

S530 9.75 3.73
S531 9.75 3L73
S532 9.75 3.31
NOTE: 3L73 refers to 3.73 gear ratio with limited slip.
Driveline System 1928

The VC label is located in the driver door jamb. The first 2 digits of the axle code indicate the rear axle and
the third digit refers to the front axle, if equipped. For information on the VC label, refer to Section 100-01 .


SECTION 205-00: Driveline System - General Information
Manual
Driveline System
Special Tool(s)
Clamp Plate, Driveshaft

205-320 (T92L-4851-C)

100-D(D78P-4201-B) or equivalent
Gauge, Differential (Traction-Lok)

205-385 (T97T-4205-B)
Runout Gauge, Drive Pinion Flange

205-319 (T92L-4851-B)
Material
Item Specification
Motorcraft High Contrast -
Hypoid Gear Marking Compound
XG-14
Threadlock and Sealer WSK-M2G351-A5
TA-25
The driveline system enables the power generated by the engine and transferred through the transmission and,
if applicable, transfer case, to place the vehicle in motion. Rotational torque received from the transmission or
transfer case is delivered to the front and rear drive axles by way of the driveshafts. The U-joints or CV joints
at the ends of the shafts allow the shafts to rotate smoothly in an allowable angle plane. The rotational torque
is introduced into the axle drive pinion which drives the differential ring gear. The ring gear is bolted to the
differential case flange on the differential. The differential divides therque between the right and left halfshaft
while permitting the halfshafts to turn at different speeds when required, such as when cornering.

Mechanical
U-joints
CV joints
Center bearings
Driveshaft tubes
Mounting brackets
Flanges
Housing and cover
damage
Differential
bearings
Differential gear
sets
Pinion bearings
4. If the cause is not visually evident, verify the symptom and GO to Symptom Chart - Driveline or GO
to Symptom Chart - NVH .
Symptom Chart - Driveline
Symptom Chart - NVH
Symptom Chart - NVH

Axle howling or whine - front or rear axle
Axle lubricant low
CHECK the lubricant level. FILL the axle to specification. REFER to Section 205-02 or Section
205-03 .
Axle housing damage
INSPECT the axle housing for damage. REPAIR or INSTALL a new axle as necessary. REFER to
Section 205-02 or Section 205-03 .

Damaged or worn wheel hub bearings
CHECK for abnormal wheel hub bearing play or roughness. REFER to Section 204-01A , Section
204-01B or Section 204-02 .
Damaged or worn differential ring and pinion
INSPECT and INSTALL a new differential ring and pinion as necessary. REFER to Section 205-02
or Section 205-03 .
Damaged or worn differential side or pinion bearings
INSPECT and INSTALL new differential side or pinion bearings as necessary. REFER to Section
205-02 or Section 205-03 .
Driveline clunk - loud clunk when shifting from REVERSE to DRIVE
Incorrect axle lubricant level
CHECK the lubricant level. FILL the axle to specification. REFER to Section 205-02 or Section
205-03 .
Excessive backlash in the axle
CHECK the axle backlash. REPAIR as necessary. REFER to Section 205-02 or Section 205-03 .
Damaged or worn pinion bearings
REPAIR or INSTALL new pinion bearings as necessary. REFER to Section 205-02 or Section
205-03 .
Damaged or worn U-joints
INSPECT the U-joints for wear or damage. INSTALL new U-joints or driveshaft as necessary.
Driveline clunk - occurs as the vehicle starts to move forward following a stop
Worn driveshaft CV joint or U-joints with excessive play
INSPECT the CV joint and U-joints for a worn condition. INSTALL a new driveshaft or U-joints as
necessary. REFER to Section 205-01 .
Loose axle mount
CHECK the axle for loose bolts. TIGHTEN to specification. REFER to Section 205-02 or Section
205-03 .
Driveline clunk - occurs during acceleration or from cruise to coast/deceleration
Damaged or worn CV joint
INSPECT the CV joint and boot. INSTALL a new CV joint as necessary. REFER to Section 205-04
or Section 205-05 .

Clicking, popping or grinding - occurs while the vehicle is turning
Inadequate or contaminated lubrication in the CV joints
CHECK the CV boots and joints for wear or damage. INSTALL new components as necessary.
REFER to Section 205-04 or Section 205-05 .
Another component contacting the halfshaft
CHECK the halfshafts and the area around the halfshafts. REPAIR as necessary.
High pitched chattering - noise from the axle when the vehicle is turning
Incorrect or contaminated lubricant
CHECK the vehicle by driving in tight circles (5 clockwise, 5 counterclockwise). FLUSH and
REFILL the axle to Specification. REFER to Section 205-02 or Section 205-03 .
Damaged or worn differential (differential side gears and pinion gears)
REPAIR or INSTALL new differential side gears or pinion gears as necessary. REFER to Section
205-02 or Section 205-03 /a>.
Buzz - buzzing noise is the same at cruise or coast/deceleration
Incorrect driveline angles
CHECK for correct driveline angles. REPAIR as necessary. REFER to Driveline Angle Measurement
in this section.
Rumble or boom - noise occurs at coast/deceleration, usually driveshaft speed-related and noticeable
over a wide range of speeds
Driveshaft is out-of-balance
CHECK the driveshaft for damage, missing balance weights or undercoating. REFER to Driveshaft
Runout and Balancing in this section.
U-joints are binding or seized
ROTATE the driveshaft and CHECK for rough operation or seized U-joints. INSTALL new U-joints
or driveshaft as necessary. REFER to Section 205-01 .
Grunting - normally associated with a shudder experienced during acceleration from a complete stop
Driveshaft CV joint binding
CLEAN the CV joint and INSTALL a new driveshaft as necessary. REFER to Section 205-01 .
Loose axle mount bolts or suspension fasteners
INSPECT the rear suspension and axle. TIGHTEN the fasteners to specification. REFER to Section
205-02 or Section 205-03 .

Howl - can occur at various speeds and driving conditions. Affected by acceleration and deceleration
Incorrect ring and pinion contact, incorrect bearing preload or gear damage
INSPECT and RE as necessary. REFER to Section 205-02 or Section 205-03 .
Chuckle - heard at coast/deceleration. Also described as a knock
Incorrect ring and pinion contact or damaged teeth on the coast side of the ring and pinion
INSPECT and REPAIR as necessary. REFER to Section 205-02 or Section 205-03 .
Knock - noise occurs at various speeds. Not affected by acceleration or deceleration
Gear tooth damage to the drive side of the ring and pinion
INSTALL a new ring and pinion. REFER to Section 205-02 or Section 205-03 .
Scraping noise - a continuous low pitched noise starting at low speeds
Worn or damaged pinion bearings
INSPECT and REPAIR or INSTALL new pinion bearings. REFER to Section 205-02 or Section
205-03 .
Driveline shudder - occurs during acceleration from a slow speed or stop
Drive axle assembly mispositioned
Section 205-02 or Section 205-03 .
Loose axle bolts
CHECK the axle for loose bolts. TIGHTEN the bolts to specification. REFER to Section 205-02 or
Section 205-03 .
Driveline angles out of specification
CHECK for correct driveline angles. REFER to Driveline Angle Measurement in this section.
U-joints binding or seized
ROTATE the driveshaft and CHECK for rough operation or seized U-joints. INSTALL new U-joints
or driveshaft as necessary. REFER to Section 205-01 .
Binding or damaged driveshaft CV joint
INSPECT the driveshaft CV joint and coupling shaft for wear or damage. INSTALL a new driveshaft
as necessary. REPAIR as necessary. REFER to Section 205-01 .
Transfer case
REFER to Section 308-07A .

Driveline vibration - occurs at cruising speeds
Worn U-joints
CHECK for wear or incorrect seating. INSTALL new U-joints or driveshaft as necessary. REFER to
Section 205-01 .
Worn or damaged driveshaft center bearing support
CHECK the insulator for damage or wear. ROTATE the driveshaft and CHECK for rough operation.
INSTALL a new driveshaft as necessary. REFER to Section 205-01 .
Loose axle pinion flange bolts
INSPECT the axle pinion flange. TIGHTEN the pinion flange bolts to specification. REFER to
Section 205-01 .
Excessive axle pinion flange runout


Information Manual
Driveshaft Runout and Balancing
Special Tool(s)

Mastertech Series MTS 4000 Driveline

Balance and NVH Analyzer (Vetronix)
Driveshaft Inspection
NOTE: Driveline vibration exhibits a higher frequency and lower amplitude than high-speed shake. Driveline
vibration isrectly related to the speed of the vehicle and is noticed at various speeds. Driveline vibration can
be perceived as a tremor in the floorpan or heard as a rumble, hum or boom.
NOTE: Refer to Specifications in this section for all runout specifications.
1. NOTE: Do not make any adjustments before carrying out a road test. Do not change the tire pressure
or the vehicle load.
Carry out a visual inspection of the vehicle. Operate the vehicle and verify the condition by
reproducing it during the road test.
The concern should be directly related to vehicle road speed, not affected by acceleration or
deceleration or could not be reduced by coasting in NEUTRAL.
100-02 .
The driveshaft should be kept at an angle equal to or close to the curb-weighted position. Use
a twin-post hoist or a frame hoist with jackstands.
3. Inspect the driveshaft for damage, undercoating or incorrectly seated U-joints. Rotate the driveshaft
slowly by hand and feel for binding or end play in the U-joint trunnions. Remove the driveshaft. For
additional information, refer to Section 205-01 . Inspect the slip yoke splines for any galling, dirt, rust
or incorrect lubrication. Clean the driveshaft or install new U-joints as necessary. Install a new
driveshaft if damaged. After any corrections or new components are installed, recheck for the
vibration at the road test speed.
If the vibration is gone, test drive the vehicle.
If the vibration persists or the driveshaft passes visual inspection, measure the driveshaft
runout.
Driveshaft Runout
1. Install the Dial Indicator Gauge with Holding Fixture. Rotate the driveshaft by turning the axle and
measure the runout at the front, the center and the rear of the driveshaft.
Driveshaft Runout and Balancing 1936

If the runout exceeds 1 mm (0.040 in) at the front or center, install a new driveshaft.
If the front and center is within 1 mm (0.040 in), but the rear runout is not, index-mark the
rear runout high point and proceed to Step 2.
If the runout is within 1 mm (0.040 in) at all points, recheck for vibration at road test speed. If
the vibration persists, balance the driveshaft. For additional information, refer to Driveshaft
Balancing in this procedure.
2. NOTE: Circular pinion flanges can be turned in 90 degree or one-fourth increments. Half-round
pinion flanges are limited to 2 positions.
Index-mark the driveshaft to the pinion flange. Disconnect the driveshaft and rotate it 180 degrees.
Reconnect the driveshaft. Recheck the runout at the rear of the driveshaft.
If the runout is still over specification, mark the high point and proceed to Step 3.
If the runout is within specification, check for the vibration at the road test speed. If the
vibration is still present, balance the driveshaft. For additional information, refer to Driveshaft
Balancing in this procedure.
3. Excessive driveshaft runout can originate in the driveshaft itself or from the pinion flange. To find the
source, compare the 2 high points previously determined.
If the index marks are close together, within 25 mm (1 in), the driveshaft is eccentric. Install a
new driveshaft.
If the marks are on opposite sides of the driveshaft, 180 degrees apart, the slip yoke or pinion
flange is responsible. Check the pinion flange runout. If the pinion flange runout exceeds
specifications, a bent pinion is indicated.
If the pinion flange and pinion runouts are within specifications, road test and check for the
vibration at the road test speed. If the vibration persists, balance the driveshaft. For additional
information, refer to Driveshaft Balancing in this procedure.
Driveshaft Balancing - Using the Mastertech Series MTS 4000 Driveline Balance and NVH Analyzer
(Vetronix)
All vehicles
1. Install the Mastertech Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix) to the
vehicle.
2. Working under the vehicle, install an accelerometer. accelerometer can be attached and mounted near

either the transmission or differential end of the driveshaft.
3. Clean an area of the driveshaft and install the reflective tape, then install the photo-tachometer sensor.
The sensor should be placed at approximately a 20-degree angle from perpendicular to the surface of
the reflective tape. Make sure the sensor does not get moved during the balance procedure.
1. Reflective tape.
2. Photo-tachometer sensor.
4. Using the Mastertech Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix), run a
driveshaft balance test with the driveshaft unmodified.
Vehicles with tapped pinion flanges
5. Label the tapped holes in the pinion flange numerically, starting at the top hole as 1. Mark the
remaining holes 2, 3 and 4. Label in the direction of rotation.
second test with the 12 mm (0.47 in) test weight set screw in the No. 1 hole, previously marked on the
pinion flange.
7. Remove the test weight, then install the weight combination directed by the Mastertech SeriesS
4000 Driveline Balance and NVH Analyzer (Vetronix).
Vehicles without tapped pinion flanges
second test with a test weight. Using a metal band, secure the test weight to the end of the driveshaft.
The weight should be placed at the end of the driveshaft tube, as close to the tube-to-yoke weld seam
as possible. Mark the location of the test weight on the driveshaft, as shown in the figure below.
1. Test weight.
2. Tube-to-yoke weld seam.
3. Driveshaft pinion flange.

Select the test weight based on driveshaft size. Larger driveshafts use 10 g (0.353 oz). Smaller
driveshafts use 5 g (0.176 oz).
9. Remove the test weight, then install the recommended weight at the position directed by the
Mastertech Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix). Using a metal band
and epoxy, secure the test weight to the driveshaft, as shown in the figure below.
1. Test weight.
2. Measure in this direction.
3. Driveshaft diameter.
4. Dectional rotation.
5. Balance weight relative to test weight centerline.
The results are displayed with respect to the location to where the test weight was placed.
All vehicles
third test to verify the repair.
Driveshaft Balancing - Hose Clamp Method
1. Install 1 or 2 hose clamps on the driveshaft, near the rear. Position of the hose clamp head(s) can be
determined through trial and error.
2. Mark the rear of the driveshaft into 4 approximately equal sectors and number the marks 1 through 4.
Install a hose clamp on the driveshaft with its head at position No. 1, as shown in the figure below.
Check for vibration at road speed. Recheck with the clamp at each of the other positions to find the
position that shows minimum vibration. If 2 adjacent positions show equal improvement, position the
clamp head between them.
3. If the vibration persists, add a second clamp at the same position and recheck for vibration.

4. If no improvement is noted, rotate the clamps in opposite directions, equal distances from the best
position determined in Step 2. Separate the clamp heads about 13 mm (1/2 in) and recheck for
vibration at the road speed.
5. Repeat the process with increasing separation until the best combination is found or the vibration is
reduced to an acceptable level.


SECTION 205-00: Driveline System - General Inrmation
Manual
Driveline Angle Measurement
Special Tool(s)
Anglemaster II Driveline
Inclinometer/Protractor
NOTE: This procedure does not apply to CV joints, flex couplers or double cardan joints that are used in
some driveshafts. This check is for single-cross and roller-style joints found in the driveshafts.
NOTE: Prior to checking driveline angularity, inspect the U-joints for correct operation.
NOTE: An incorrect driveline angle can cause a vibration or shudder. For additional information, refer to
Section 100-04 .
NOTE: Driveline angularity is the angular relationship between the engine crankshaft, the driveshaft and the
rear axle pinion. Factors determining driveline angularity include ride height, rear spring and engine mounts.
All vehicles
1. Carry out the following preliminary setup steps:

Inspect the U-joints for correct operation.
Park the vehicle on a level surface such as a drive-on hoist, or back onto a front end
alignment rack.
Verify the curb position ride height is within specifications with the vehicle unloaded and all
of the tires are inflated to their normal operating pressures.
Calibrate the Anglemaster II Driveline Inclinometer/Protractor by placing it on a clean, flat
level section of the frame rail and press the ALT-ZERO button.
Vehicles with flat-flanged, split-pin or slip-flanged U-joints
2. NOTE: If equipped, remove the snap ring to allow access to the base of the U-joint cup. Make sure
the Anglemaster II Driveline Inclinometer/Protractor is seated against the U-joint cup.
NOTE: Rotate the driveshaft until the flange U-joint cup is parallel with the floor. This will simplify
taking measurements.
To check the U-joint operating angle, install the Anglemaster II Driveline Inclinometer/Protractor.
Check and record the flange angle as angle A.
Driveline Angle Measurement 1941

3. Using the Anglemaster II Driveline Inclinometer/Protractor, measure the slope of the connecting
component. Record the measurement of the component angle as angle B.
Multiple piece driveshafts
4. NOTE: Repeat this step for each center support bearing on the driveshaft.
NOTE: It is not necessary to remove the U-joint snap ring, if equipped, for these measurements.
Using the Anglemaster II Driveline Inclinometer/Protractor, measure the slope of the components in
front and behind the center support bearing U-joint in the area indicated. Record the front component
as angle A and the rear component as angle B.
All vehicles
5. NOTE: When 2 connected components slope in the same direction, subtract the smallest number
from the larger number to find the U-joint operating angle. When 2 connected components slope in
the opposite direction, add the measurements to find the U-joint operating angle.
Calculate the difference in the slope of the components to determine the U-joint operating angle.
The U-joint operating angle is the angle formed by 2 yokes connected by a cross and bearing
kit. Ideally, the operating angles on each connection of the driveshaft must:
be equal or within one degree of each other.
have a 3 degree maximum operating angle.
have at least one-half of one degree continuous operating angle.
6. If the angle is not within specifications, repair or adjust to obtain the correct angle. Inspect the engine
mounts, transmission mounts, center support bearing mounting, rear suspension, rear axle, rear axle
mounting or the frame for wear or damage.


SECTION 205-01: Driveshaft 2011 Expedition, Navigator Workshop Manual

Material

Capacity
Premium Long-Life Grease ESA-M1C75-B -
XG-1-C or XG-1-K (US);
CXG-1-C (Canada)
TA-25
Center support bearing bracket bolts 48 35
Driveshaft flange bolts (front and rear) 103 76
Front driveshaft bolt and washer kits 55 41
Front flange-to-pinion flange bolts 55 41
Rear flange-to-transfer case flange bolts 55 41
Stabilizer bar bracket nuts 55 41


Driveshaft
NOTE: All driveshafts are balanced. If undercoating the vehicle, protect the driveshaft and U-joints to
prevent overspray of any undercoating material.
Vehicles have the following types of driveshafts:
Front driveshaft with CV joints at the front and rear. The front driveshafts are not serviced
One-piece rear driveshafts with a front and a rear U-joint flange
Two-piece rear driveshafts with a front U-joint, center bearing with a slip joint and a flanged U-joint
at the rear
Driveshafts are used to transfer movement from the transmission or transfer case to the front or rear axle. The
driveshaft is composed of the U-joints, CV joints, connecting shafts and the attaching yokes. Some vehicles
are equipped with a center support bearing. The center support bearing is prelubricated and sealed for the life
of the bearing.
Driveshafts differ in length, diameter and type of yoke to accommodate various wheelbase and powertrain
combinations.
Driveshaft 1945

Universal Joints
U-joints are composed of the following:
Spiders
Trunnions
Grease seals
Needle rollers
Bearing cups
Thrust washers
Snap rings
The U-joint is a method of connecting the driveshaft to the drive axle. A U-joint allows the angles of the
output shafts, driveshafts and pinions to rotate smoothly while constantly accelerating and decelerating. The
U-joint is lubricated for the life of the vehicle.
Universal Joints 1946


Driveshaft
Driveshaft 1947

Driveshaft - Front

1 4B496 Rear flange-to-transfer case flange bolt and washer kits
2 4B496 Front flange-to-pinion flange bolt and washer kits
3 W520213 Stabilizer bar bracket nuts (4 required)
4 3B353 Stabilizer bar brackets (2 required)
5 4A376 Driveshaft
1. With the vehicle in NEUTRAL, position the vehicle on a hoist. For additional information, refer to
Section 100-02 .
2. Index-mark the front flange to the pinion flange.
Index-mark the rear flange to the transfer case flange.
4. Remove and discard the 6 rear flange-to-transfer case flange bolts and 3 washers.
Driveshaft - Front 1948

5. Remove and discard the 6 front flange-to-pinion flange bolts and 2 washers.
6. Remove and discard the 4 stabilizer bar bracket nuts and allow the stabilizer bar to swing downward.
7. Remove the front driveshaft from the vehicle.
Driveshaft - Front 1949


Driveshaft - Rear
Material
Item Specification
TA-25
Four-Wheel Drive (4WD) Vehicles

1 N800594 Driveshaft flange bolt (4 required)
2 4602 Driveshaft
Rear Wheel Drive (RWD) Vehicles
Driveshaft - Rear 1950

1 N800594 Driveshaft front flange bolt (4 required)

2 N897487 Center support bearing bracket bolt (2 required)
3 N800594 Driveshaft rear flange bolt (4 required)
4 4R602 Driveshaft
Removal and Inlation
All vehicles
100-02 .
2. Index-mark the driveshaft flange to the pinion flange.
3. Index-mark the driveshaft slip yoke to the transfer case housing.
4. Remove and discard the 4 driveshaft flange bolts.
5. NOTICE: The driveshaft flange fits tightly on the pinion flange pilot. Never hammer on the
driveshaft or any of its components to disconnect the driveshaft from the pinion flange. Pry only
in the area shown, with a suitable tool, to disconnect the driveshaft flange from the pinion flange
or damage to the component may occur.
Using a suitable tool, disconnect the driveshaft flange from the pinion flange.
6. NOTE: Align the original index-marks at the transfer case. Do not rotate the driveshaft when
removing the slip yoke from the transfer case output shaft.
Remove the driveshaft.
Rear Wheel Drive (RWD) Vehicles 1951

Mark the transfer case output shaft to the transfer case housing after removing the driveshaft.
Rear Wheel Drive (RWD) vehicles
7. Index-mark the driveshaft flanges for correct alignment during installation.
8. Remove and discard the 4 driveshaft front flange bolts.
9. Remove and discard the 4 driveshaft rear flange bolts.
10. NOTICE: The driveshaft flange fits tightly on the pinion flange pilot. Never hammer on the
driveshaft or any of its components to disconnect the driveshaft from the pinion flange. Pry only
in the area shown, with a suitable tool, to disconnect the driveshaft flange from the pinion flange
Using a suitable tool, disconnect the driveshaft flange from the pinion flange.
11. Remove the 2 driveshaft center bearing bolts, then remove the driveshaft.
Discard the driveshaft center bearing bolts.
Installation
4WD vehicles

1. Align all the index marks and install the driveshaft slip yoke into the transfer case housing.
2. NOTICE: The driveshaft flange fits tightly on the pinion flange pilot. To make sure that the
driveshaft flange seat squarely on the pinion flange pilot, tighten the driveshaft flange bolts
evenly in a cross pattern or damage to the component may occur.
Align the index marks and install the driveshaft flange and the 4 driveshaft flange bolts.
RWD vehicles
3. NOTE: If new driveshaft center bearing bolts are not available, coat the threads of the original
driveshaft center bearing bolts with threadlock sealer.
Position the driveshaft center bearing and hand-tighten the 2 new center support bearing bracket bolts
until the driveshaft is mounted to the flanges.
4. Install the 4 new driveshaft front flange bolts.

Tighten the bolts to 103 Nm (76 lb-ft).
5. NOTICE: The driveshaft flange fits tightly on the pinion flange pilot. To make sure that the
driveshaft flange seats squarely on the pinion flange pilot, tighten the driveshaft flange bolts
evenly in a cross pattern or damage to the component may occur.
Install the 4 new driveshaft rear flange bolts.



Driveshaft Slip Yoke Boot
Material
Item Specification
Premium Long-Life Grease ESA-M1C75-B
XG-1-C or XG-1-K (US); CXG-1-C
(Canada)

1 3B478 Clamp (2 required)
2 4421 Boot
1. Remove the driveshaft. For additional information, refer to Driveshaft - Rear in this section.
2. Index-mark the driveshaft to the center bearing for correct alignment during installation.
3. Remove clamps and disconnect the slip yoke boot.
Driveshaft Slip Yoke Boot 1955

4. Separate the driveshaft.
5. Remove the slip yoke boot.
6. NOTE: Lubricate the slip yoke splines with premium long-life grease.
Align the index marks for correct alignment.



Driveshaft - Exploded View
Front, Expedition and Navigator

1 4A376 Driveshaft assembly
2 4682 CV joint washers (2 required)
3 4N272 Front CV bolt (6 required)
4 4682 Rear CV washers (3 required)
5 4N272 Rear CV bolt (6 required)
Rear - Navigator Four-Wheel Drive (4WD), Expedition 4WD and Rear Wheel Drive (RWD)

1 4A378 Driveshaft flange yoke
2 N800594 Bolts
3 - Snap rings (part)
4 4635 U-joint assemblies
5 4602 Driveshaft assembly
6 4841 Driveshaft slip yoke (Expedition/Navigator)
7 4A335 Driveshaft slip yoke (Expedition EL/Navigator L)
Driveshaft - Exploded View 1958

Rear, Navigator Rear Wheel Drive (RWD)

1 N800594 Driveshaft front flange bolt (4 required)
2 N800594 Driveshaft rear flange bolt (4 required)
3 N897487 Driveshaft center bearing bolt (2 required)
4 4R602 Driveshaft assembly
5 - Front snap rings
6 4A378 Front driveshaft flange (part of 4R602)
7 4635 Front U-joint
8 - Rear snap rings
9 4A378 Driveshaft flange (part of 4R602)
10 4635 Rear U-joint
11 3B478 Clamp
12 3B478 Clamp
13 4421 Boot
ol start="1">
For additional information, refer to the procedures in this section.
Rear, Navigator Rear Wheel Drive (RWD) 1959

Rear, Navigator Rear Wheel Drive (RWD) 1960


Driveshaft Universal Joint - Single Cardan
Special Tool(s)

205-086 (T74P-4635-C)
Disassembly
1. Remove the driveshaft. For additional information, refer to Driveshaft - Front or Driveshaft - Rear in
this section.
2. NOTICE: Do not clamp the driveshaft in the jaws of a vise or a similar holding fixture or
damage to the component may occur.
Carefully place the driveshaft on a suitable workbench.
3. NOTE: Index-mark the driveshaft components relative to the driveshaft tube. Make sure all
components are reassembled in the same relationship to maintain correct balance.
Index the driveshaft and driveshaft components.
4. Position the C-Frame and Screw Installer/Remover in a vise.
5. Remove the snap rings from the U-joint.
Driveshaft Universal Joint - Single Cardan 1961

6. NOTE: If necessary, use a pair of pliers to remove a bearing cup if it cannot be pressed out all the
way.
Remove the driveshaft flange yoke.
1. Position the driveshaft flange in the C-Frame and Screw Installer/Remover.

2. Press out the bearing cup.
3. Rotate the driveshaft flange yoke.
4. Press on the spider to remove the remaining bearing cup.
5. Remove the driveshaft flange yoke.
7. Repeat the previous step to remove the remaining bearing cups and spider from the driveshaft.
8. Clean the yoke area at the end of the driveshaft and flange yoke.
Assembly
NOTE: U-joint service kits are to be installed as complete assemblies only. Do not use components from
other U-joints.
1. Clamp the C-Frame and Screw Installer/Remover in a vise.
2. Install a new bearing cup.

1. Start a new bearing cup into the driveshaft yoke.
2. Position a new spider in the driveshaft yoke.
3. Install the driveshaft into the C-Frame and Screw Installer/Remover.
4. Press the bearing cup below the yoke surface.
3. Remove the driveshaft from the C-Frame and Screw Installer/Remover and install the snap ring.

4. Repeat the previous steps to install the remaining bearing cups.
5. NOTE: Do not strike the bearings. If binding, strike the yoke with a brass or plastic hammer.
Check the U-joint for freedom of movement.

SECTION 205-02: Rear Drive Axle/Differential Ford 2011 Expedition, Navigator

9.75-Inch Ring Gear Workshop Manual
Material

Capacity
Additive Friction Modifier EST-M2C118-A
XL-3 (US); CXL-3 (Canada)
Motorcraft High Contrast
Hypoid Gear Marking
Compound
XG-14
Motorcraft SAE 75W-140 WSL-M2C192-A
Synthetic Rear Axle Lubricant and GL-5
XY-75W140-QL (US);
CXY-75W140-1L (Canada)
CXG-1-C (Canada)
TA-30
Item Specification
Axle capacity conventional (ribbed cover) 2.01L (4.25 pt)
Axle capacity conventional (smooth cover) 2.01L (4.25 pt)
Axle capacity Traction-Lok (ribbed cover) 1.89L (4 pt) + 118 ml (4 oz) friction modifier a
Axle capacity Traction-Lok (smooth cover) 1.89L (4 pt) + 118 ml (4 oz) friction modifier a
Backlash Specifications
Backlash between ring gear and pinion teeth 0.208-0.305 mm (0.008-0.012 in)
Differential case maximum runout 0.076 mm (0.003 in)
Pinion flange maximum radial runout in assembly 0.203 mm
(0.008 in T.I.R.)
Ring gear maximum backlash variation between teeth 0.102 mm (0.004 in)
Rotational Torque Ranges
Minimum breakaway torque (Traction-Lok) 27 Nm (20 lb-ft)
Pinion bearing preload 1.8-3.3 Nm (16-29 lb-in)
a Install friction modifier in axle before installing lubricant.


Adapter 2.2 20
Differential bearing cap bolts 105 77
Differential housing cover bolts 32 24
Differential pinion shaft lock bolt 30 22
Differential ring gear bolts a
Drive pinion nut a
Insulator stud nuts 135 100
Torque arm nut a
Torque arm-to-rear axle housing bolts a

SECTION 205-02: Rear Drive Axle/Differential - Ford 2011 Expedition, Navigator Workshop
9.75-Inch Ring Gear Manual
Rear Drive Axle and Differential
The rear drive axle consists of the following:
A cast iron housing and a cast aluminum differential housing cover.

Differential housing cover that uses silicone sealant as a gasket.
The hypoid-design gearset consists of a 9.75-inch differential ring gear and a drive pinion gear.
Two opposed pinion bearings support the drive pinion gear in the differential housing.
A drive pinion collapsible spacer, located on the drive pinion gear shaft, maintains pinion bearing
preload.
The pinion nut adjusts the preload.
Differential bearing shims, located between the differential bearing cups and the differential housing,
adjust the differential ring gear backlash and the differential bearing preload.
The differential case is a 1-piece design with 2 openings to allow for assembly of the internal
components and lubricant flow.
Two opposed differential bearings support the differential case in the differential housing.
Removable drential bearing caps retain the differential assembly in the differential housing.
A differential pinion shaft supports 2 differential pinion gears.
A differential pinion shaft lock bolt retains the differential pinion shaft in the differential case.
A circlip, located on the stub shaft, holds the halfshaft in the differential case. When installed, the
circlip engages a groove in the differential side gear.
The pinion gears engage the differential side gears, to which the halfshafts are splined.
The rear axle requires SAE 75W-140 Synthetic Rear Axle Lubricant XY-75W140-QL (US);
CXY-75W140-1L (Canada); or equivalent meeting Ford specification WSL-M2C192-A. If equipped
with a Traction-Lok, 4 ounces of Friction Modifier XL-3 (US); CXL-3 (Canada); or equivalent
meeting Ford specification EST-M2C118-A must be added.
The rear axle ratio may be verified by checking the printed label on the axle housing. If worn or not
visible, the Vehicle Identification Number (VIN) or the Vehicle Certification (VC) label may be used.
The rear drive axle receives rotational torque from the driveshaft through the pinion flange. The drive pinion
turns the differential case. The differential case has a shaft with a pinion gear on each end. The shaft is bolted
through the case and allows the pinion gears to roll with the differential side gears, providing the differential
action letting the splined halfshafts drive at different speeds as needed when cornering.
Rear Drive Axle and Differential 1966


Rear Drive Axle and Differential

Ring Gear Backlash Adjustment
Special Tool(s)
Dial Indicator Gauge With Holding

Fixture
100-002 (TOOL-4201-C)
Gauge, Clutch Housing
308-021 (T75L-4201-A)
>
Holding Fixture, Transmission
307-003 (T57L-500-B)
Installer, Differential Shim

205-228 (T85T-4067-AH)
Material
Item Specification
Hypoid Gear Marking
Compound
XG-14
Motorcraft SAE 75W-140 WSL-M2C192-A and
Synthetic Rear Axle Lubricant GL-5
XY-75W140-QL (US);
TA-30
1. Remove the rear axle assembly. For additional information, refer to Axle Assembly in this section.
2. Remove the 4 bolts retaining the torque arm to the rear axle housing. >
3. Remove the 12 bolts and the differential housing cover.

Drain the lubricant.
Ring Gear Backlash Adjustment 1969

4. Using the Transmission Holding Fixture, mount the differential housing to a work bench.
5. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, measure the
differential ring gear backlash.
1. Attach the Dial Indicator Gauge with Holding Fixture.
2. Position the Clutch Housing Gauge tip centrally on a drive tooth.
4. Turn the differential ring gear without turning the drive pinion gear. Record the Dial Indicator
Gauge reading. The allowable backlash is mm (0.008 in) to 0.305 mm (0.012 in).
To correct for a high or low backlash, proceed as follows.
6. To correct for high or low backlash, increase the thickness of one differential bearing shim and
decrease the thickness of the other differential bearing shim by the same amount. Refer to the
following tables when adjusting the backlash.
Backlash Thickness
Change Change
Required Required
mm Inch mm Inch
0.025 0.001 0.050 0.002
0.050 0.002 0.050 0.002
0.076 0.003 0.101 0.004
0.101 0.004 0.152 0.006

0.127 0.005 0.152 0.006

0.152 0.006 0.203 0.008
0.177 0.007 0.254 0.010
0.203 0.008 0.254 0.010
0.228 0.009 0.304 0.012
0.254 0.010 0.355 0.014
0.279 0.011 0.355 0.014
0.304 0.012 0.406 0.016
0.330 0.013 0.457 0.018
0.335 0.014 0.457 0.018
0.381 0.015 0.508 0.020
Differential Shim Size Chart 4067
Dimension A
Stripes and Color Code mm Inch
2 - C-COAL 7.7978-7.8105 0.3070-0.3075
1 - C-COAL 7.7470-7.7597 0.3050-0.3055
5 - BLU 7.6962-7.7089 0.3030-0.3035
4 - BLU 7.6454-7.6581 0.3010-0.3015
3 - BLU 7.5946-7.6073 0.2990-0.2995
2 - BLU 7.5458-7.5565 0.2970-0.2975
5 - PINK 7.4422-7.4549 0.2930-0.2935
4 - PINK 7.3914-7.4041 0.2910-0.2915
3 - PINK 7.3406-7.3533 0.2890-0.2895
2 - PINK 7.2898-7.3025 0.2870-0.2875
1 - PINK 7.2390-7.2517 0.2850-0.2855
5 - GRN 7.1882-7.2009 0.2830-0.2835
4 - GRN 0.2810-0.2815
3 - GRN 7.0866-7.0993 0.2790-0.2795
2 - GRN 7.0358-7.0485 0.2770-0.2775
1 - GRN 6.9850-7.0485 0.2750-0.2755
5 - WH 6.9342-6.9469 0.2730-0.2735
4 - WH 6.8834-6.8961 0.2710-0.2715
3 - WH 6.8326-6.8453 0.2690-0.2695
2 - WH 6.7818-6.7945 0.2670-0.2675
1 - WH 6.7310-6.7437 0.2650-0.2655
5 - YEL 6.6802-6.6929 0.2630-0.2635
4 - YEL 6.6294-6.6421 0.2610-0.2615
3 - YEL 6.5786-6.5913 0.2590-0.2595
2 - YEL 6.5278-6.5405 0.2570-0.2575
1 - YEL 0.2550-0.2555

5 - ORNG 6.4262-6.4389 0.2530-0.2535

4 - ORNG 6.3754-6.3881 0.2510-0.2515
3 - ORNG 6.3246-6.3373 0.2490-0.2495
2 - ORNG 6.2738-6.2865 0.2470-0.2475
1 - ORNG 6.2223-6.2357 0.2450-0.2455
2 - RED 6.1722-6.1849 0.2430-0.2435
1 - RED 6.1214-6.1341 0.2410-0.2415
7. NOTICE: Mark the position and location of the differential bearing caps as the arrows may not
be visible. Always install the differential bearing caps in their original locations and positions or
Remove the 4 differential bearing cap bolts and the 2 bearing caps.
Remove the differential assembly.
8. Measure the thickness of the selected right and left bearing shims.
9. NOTE: Differential bearing shims are to be installed with the chamfer facing outboard.
To establish differential bearing preload, using the Differential Shim Installer increase both the left
and right differential bearing shim thickness by 0.152 mm (0.006 in).
10. Install the 2 bearing caps and 4 bolts.

11. Rotate the differential assembly several times to verify the differential bearings have seated correctly.
12. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, recheck the
differential ring gear backlash.
13. Apply marking compound and rotate the differential assembly 5 complete revolutions.
14. Verify an acceptable pattern check. For additional information, refer to Tooth Contact Pattern Check
in Section 205-00 .

15. NOTE: The machined surfaces on the differential housing and the differential housing cover must be
clean and free of oil before applying the new silicone sealant. Cover the inside of the axle before
cleaning the machined surface to prevent contamination.
NOTE: Install the differential housing cover within 15 minutes of applying the silicone material.
NOTE: Allow the sealant to cure for one hour before filling the axle with lubricant.
Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover
mounting surface.
Use silicone gasket and sealant.
16. Install the differential housing cover and the 12 bolts.

17. Position the torque arm to the rear axle housing and install the 4 bolts in the following sequence:
Tighten the 4 bolts to 203 Nm (150 lb-ft).
Loosen the 4 bolts one revolution.
18. Install the rear axle assembly. For additional information, refer to Axle Assembly in this section.
19. Fill the axle assembly with the specified lubricant.

Stub Shaft Pilot Bearing and Seal
Special Tool(s)
Adapter for 303-224 (Handle)

205-153 (T80T-4000-W)
Bearing Remover
307-318 (T94P-77001-KH)
Installer, Halfshaft Pilot Bearing

205-504
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
XY-75W140-QL (US);

1 1102 Stub shaft bearing
2 4B416 Stub shaft oil seal
NOTE: The stub shaft seals must be replaced whenever the hafshafts are removed.
1. Remove the halfshaft assembly. For additional information, refer to Section 205-05 .
Stub Shaft Pilot Bearing and Seal 1974

2. NOTE: If removing the stub shaft pilot bearing oil seal only, engage the tangs of the Bearing
Remover on the stub shaft pilot bearing oil seal only.
Using the Slide Hammer and Bearing Remover, remove and discard the stub shaft pilot bearing and
the stub shaft pilot bearing oil seal.
3. Inspect the seal journal for rust, nicks and scratches. Polish the seal journal surface with fine crocus
cloth, if necessary.
4. Lubricate the new stub shaft pilot bearing with axle lubricant.
5. NOTE: Installation of the stub shaft pilot bearing or stub shaft oil seal without the correct tools can
result in early bearing or seal failure. If the stub shaft pilot bearing becomes cocked in the bore during
installation, remove it and install a new one.
Place the stub shaft pilot bearing onto the Halfshaft Pilot Bearing Installer and Adapter.
6. Install the stub shaft pilot bearing into the rear axle housing bore.
7. NOTE: Do not disassemble the new oil seal.
NOTE: Use a tool like the Lisle LIS17850 to avoid interference with the suspension components.
Install the new seal onto a suitable installer.
8. NOTICE: Strike only the handle. Directly striking the installer tool will damage the seal.
Carefully align the stub shaft pilot bearing seal with the housing bore and install the stub shaft pilot
bearing seal flush in the differential housing.
9. NOTE: If a feeler gauge of the specification shown in the illustration can be inserted between the
stub shaft oil seal and the differential housing, the stub shaft seal is not seated correctly. Remove the

stub shaft oil seal and install a new stub shaft oil seal.
Make sure the stub shaft oil seal is correctly seated in the differential housing.
10. NOTE: Inspect the stub shaft seal journal for rust, nicks or scratches prior to installing the halfshaft.
Polish the seal journal with fine crocus cloth, if required.
Install the halfshaft. For additional information, refer to Section 205-05 .

Drive Pinion Flange and Drive Pinion Seal
Special Tool(s)
2 Jaw Puller
Holding Fixture, Drive Pinion Flange

205-126 (T78P-4851-A)
Installer, Drive Pinion Flange

205-233 (T85T-4851-AH)
Installer, Drive Pinion Oil Seal

205-208 (T83T-4676-A)
Material
Item Specification
XY-75W140-QL (US);
CXG-1-C (Canada)
Item Description
1 4320 Drive pinion nut
2 4851 Drive pinion flange
3 4676 Drive pinion oil seal
Drive Pinion Flange and Drive Pinion Seal 1977

4 4010 Axle housing

Removal
NOTICE: This operation disturbs the pinion bearing preload. Carefully reset the pinion bearing
preload during installation or damage to the component may occur.
NOTE: Remove the rear wheel and tire assemblies, brake calipers and brake discs to prevent brake drag
during the drive pinion bearing preload adjustment.
1. Remove the rear brake discs. For additional information, refer to Section 206-04 .
2. Remove the rear driveshaft assembly. For additional information, refer to Section 205-01 .
3. Install a Nm (lb-in) torque wrench on the nut and record the torque necessary to maintain rotation of
the drive pinion gear through several revolutions.
4. NOTICE: Install a new pinion nut with the same color as the original if not replacing the
collapsible spacer. If a new collapsible spacer is installed, install the nut in the kit or damage to
the component may occur.
Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, remove the pinion nut.
Discard the nut.
5. Index-mark the drive pinion flange and the drive pinion gear stem to maintain initial balance during
installation.
6. Using the 2 Jaw Puller, remove the drive pinion flange.

7. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer
until the pinion seal is removed.
Installation
1. Lubricate the lips of the new drive pinion seal with grease.
2. NOTE: If the drive pinion seal becomes misaligned during installation, remove it and install a new
seal.
Using the Drive Pinion Oil Seal Installer, install the drive pinion seal.
3. Lubricate the drive pinion flange splines with rear axle lubricant.
4. NOTE: Disregard the index marks if installing a new drive pinion flange.
Position the drive pinion flange.
5. Using the Drive Pinion Flange Installer, install the drive pinion flange.

6. NOTICE: The color on the rear face of the drive pinion nut is critical to this repair. Use the
same color new drive pinion nut for installation as the original. If a new collapsible spacer must
be installed for pinion bearing preload reduction, install the nut supplied with the new spacer or
Select the correct drive pinion nut for installation.
7. Position the new drive pinion nut.
8. NOTICE: Do not under any circumstance loosen the nut to reduce preload. If it is necessary to
reduce preload, install a new drive pinion collapsible spacer. If a new collapsible spacer must be
installed for pinion bearing preload reduction, install the nut supplied with the new spacer or
NOTE: Remove the Drive Pinion Flange Holding Fixture while taking preload readings with the Nm
(inch-pound) torque wrench.
Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, tighten the nut.
Rotate the pinion occasionally to make sure the pinion bearings seat correctly. Take frequent
pinion bearing torque preload readings by rotating the drive pinion gear with a Nm (lb-in)
torque wrench.
If the preload recorded prior to disassembly is lower than the specification for used bearings,
tighten the nut to specification. If the preload recorded prior to disassembly is higher than the
specification for used bearings, tighten the nut to the original reading as recorded.
Refer to the torque specification for used pinion bearings in the Specifications portion of this
section.
9. NOTICE: The driveshaft flange yoke fits tightly on the pinion flange pilot. To make sure that
the yoke seats squarely on the flange, tighten the bolts evenly in a cross pattern as shown or

NOTE: Align the index marks.
Install the rear driveshaft. For additional information, refer to Section 205-01 .
10. Install the rear brake discs. For additional information, refer to Section 206-04 .
11. Install the rear wheel and tire. For additional information, refer to Section 204-04 .

SECTION 205-02: Rear Drive Axle/Differential - Ford 9.75-Inch 2011 Expedition, Navigator
Ring Gear Workshop Manual
Procedure revision date:
REMOVAL AND INSTALLATION
08/12/2010
Rear Axle Housing Support Insulator
Special Tool(s)
Adapter for 204-S127

204-128 (T86P-5638-AH1)
Forcing Screw, Rear Differential Housing

Bushing
205-528/4
Installer, Drive Pinion Bearing
205-488
Installer, Rear Differential Housing Bushing

205-528/2
Plate, Bearing/Oil Seal

205-090 (T75L-1165-B)
Receiver Cup, Rear Differential Housing

Bushing
205-528/3
Remover, Rear Differential Housing
Bushing
205-528/1

1 W708634-S440 Insulator stud nuts (2 required)
2 4B425 Insulator bushings (2 required)
3 4033 Differential housing cover
Removal
Rear Axle Housing Support Insulator 1982

2. Insert the Rear Differential Housing Bushing Forcing Screw through the Adapter and the frame
support insulator.
3. Thread the Rear Differential Housing Bushing Remover on the Rear Differential Housing Bushing
Forcing Screw.
4. Tighten the Rear Differential Housing Bushing Forcing Screw to remove the frame support insulator.
5. Remove the 4 bolts attaching the torque arm to the axle housing.
6. Measure and record the distance the insulator extends from the face of the torque arm.
7. Using a suitable press and the Rear Differential Housing Bushing Remover, Drive Pinion Bearing
Installer and Bearing/Oil Seal Plate, remove the torque arm insulator from the torque arm.

Installation
1. Using a suitable press and the Rear Differential Housing Bushing Remover, Drive Pinion Bearing
Installer and Bearing/Oil Seal Plate, install the new torque arm insulator to the previously recorded
depth.
2. Position the Rear Differential Housing Bushing Forcing Screw and Rear Differential Housing
Bushing Receiver Cup on the rear of the crossmember.
3. Position the new insulator and thread the Rear Differential Housing Bushing Installer on the Rear
Differential Housing Bushing Forcing Screw.
4. Tighten the forcing screw to seat and position the new insulator.
5. Position the torque arm to the rear axle housing and install the 4 bolts in the following sequence.
Loosen the 4 bolts one revolution.


08/12/2010
Axle Assembly

1 W808684 Insulator stud nuts (2 required)
2 W506568 Torque arm bolt
3 W708634 Torque arm nut
NOTICE: Suspension fasteners are critical parts because they affect performance of vital parts systems
and their failure may result in major service expense. New parts must be installed with the same part
numbers or equivalent part, if installation becomes necessary. Do not use a replacement part of lesser
quality or substitute design. Torque values must be used as specified during reassembly to make sure of
correct retention of these parts.
100-02 .
2. Remove the rear driveshaft assembly. For additional information, refer to Section 205-01 .
3. Remove the halfshafts. For additional information, refer to Section 205-05 .
4. Remove the rear stabilizer bar. For additional information, refer to Section 204-02 .
5. Using a suitable jack, support the axle housing.
Axle Assembly 1986

6. NOTE: Spare wheel removed for clarity.
Remove the 2 insulator stud nuts.
7. Remove the front torque arm nut.

8. NOTE: Move the axle housing forward to clear the rear mounting studs from the bushings.
Lower the axle housing from the vehicle.
Axle Assembly 1987

Axle Assembly 1988

08/12/2010
Differential Ring And Pinion
Special Tool(s)
2 Jaw Puller

205-159 (T80T-4020-F42)

205-160 (T80T-4020-F43)
Depth Gauge/Aligner, Drive Pinion

205-226 (T85T-4020-AH1)

205-383 (T97T-4020-B)
Gauge Tube, Drive Pinion

205-377 (T97T-4020-A)

205-126 (T78P-4851-A)

307-003 (T57L-500-B)
Installer, Differential Carrier Bearing

205-D044 (D81T-4221-A) or equivalent
Installer, Drive Pinion Bearing Cone

205-488
Installer, Drive Pinion Bearing Cup

205-024 (T67P-4616-A)

205-233 (T85T-4851-AH)
Differential Ring And Pinion 1989


205-208 (T83T-4676-A)
Installer, Rear Axle Pinion Bearing Cup

205-387 (T97T-4628-A)

205-852

205-090 (T75L-1165-B)
Protector, Drive Pinion Thread

205-229 (T85T-4209-AH)
Puller, Bearing
Step Plate
205-D061 (D83T-4205-C2) or equivalent
Material
Item Specification
XY-75W140-QL (US);
Premium Long-LifeGrease ESA-M1C75-B
CXG-1-C (Canada)


1 W720586 Differential housing cover bolt (12 required)
3 - Differential bearing cap bolts (part of 4010) (4
required)
4 - Differential bearing caps (part of 4010) (2
required)
5 4067 Differential bearing shims
6 4222 Differential bearing cups
7 4221 Differential bearings
8 4216 Differential ring gear bolt (12 required)
9 4204 Differential assembly
10 - Differential ring gear (part of 4209)
11 - Differential pinion gear (part of 4209)
12 4266 Drive pinion collapsible spacer
13 4663 Drive pinion bearing adjustment shim
14 4630 Inner drive pinion bearing
15 4670 Inner drive pinion bearing cup
Differential
4010
housing
17 4616 Outer drive pinion bearing cup
18 4621 Outer drive pinion bearing
19 4670 Drive pinion oil slinger
20 4676 Drive pinion oil seal
Removal

2. Remove the 4 bolts retaining the torque arm to the rear axle housing.
3. Remove and discard the 12 bolts and the differential housing cover.
Remove the 4 bolts and the 2 differential bearing caps.
6. NOTE: Use wood blocks to avoid damaging the differential housing.
NOTE: Tag the bearing caps and shims for location as removed.
Position wood blocks at the top and bottom of the differential assembly and pry the differential
assembly and the differential bearing shims out of the differential housing.

7. Using the 2 Jaw Puller and Step Plate, remove the differential bearing.
Repeat for the other side.
8. Remove and discard the 12 ring gear bolts.
9. NOTICE: Be careful not to damage the ring gear bolt hole threads.
Insert a punch in the ring gear bolt holes and drive the differential ring gear off.
10. Using the Drive Pinion Flange Holding Fixture, hold the pinion flange to remove and discard the
pinion nut.

11. Using the 2 Jaw Puller, remove the pinion flange.
12. Use a screwdriver to force up the metal flange of the drive pinion oil seal. Install gripping pliers and
strike with a hammer to remove the drive pinion oil seal.
13. Remove the drive pinion oil seal deflector, drive pinion oil seal slinger and the outer pinion bearing.
14. Using the Drive Pinion Thread Protector and a soft-faced hammer, remove the differential pinion gear
from the differential housing.
15. Remove and discard the drive pinion collapsible spacer.

16. Using the Bearing Puller and a suitable shop press, remove and discard the inner drive pinion bearing.
17. NOTE: Using a micrometer, measure the drive pinion bearing adjustment shim thickness. Use this
measurement as a reference to compare to the shim gauge reading taken prior to installing the pinion
bearing.
Remove the drive pinion bearing adjustment shim.
18. Using a brass drift and a hammer, remove any damaged differential drive pinion bearing cups from
the differential housing. Tap alternately on each side of the cup to prevent it from cocking in the bore.
Installation
1. Position the Drive Pinion Bearing Cup Installer, Rear Axle Pinion Bearing Cup Installers and the
inner and outer drive pinion bearing cups in their respective bores.
1. Place the Rear Axle Pinion Bearing Cup Installer on the outer drive pinion bearing cup.
2. Place the Rear Axle Pinion Bearing Cup Installer on the inner drive pinion bearing cup.
3. Install the Drive Pinion Bearing Cup Installer.

2. Tighten the Drive Pinion Bearing Cup Installer to fully seat the differential drive pinion bearing.
3. NOTE: If a feeler gauge of the specification shown can be inserted between a cup and the bottom of
its bore at any point around the cup, the cup is not correctly seated.
Make sure the differential pinion bearing cups are correctly seated.
4. NOTICE: Use the same drive pinion bearings and the drive pinion bearing adjustment shim
from the drive pinion bearing adjustment shim selection procedure for final assembly or
NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil
provides adequate lubricant without upsetting the drive pinion bearing preload settings.
Install the new drive pinion bearings and Drive Pinion Depth Gauge/Aligner, Drive Pinion Gauge
Tube, Drive Pinion Depth Gauge/Aligner and Adapters as shown.


1 4621 Outer pinion bearing
2 205-160 Adapter for 205-S127
3 4630 Inner pinion bearing
4 205-383 Depth Gauge/Aligner, Drive Pinion
5 205-159 Adapter for 205-S127
6 205-377 Drive Pinion Gauge Tube
8 4010 Rear axle housing outer (front) pinion bearing
9 205-111 Adapter for 205-S127
5. NOTE: This step duplicates drive pinion bearing preload.
Tighten the Adapter to the specified rotational torque.
Tighten to 2.2 Nm (20 lb-in) rotational torque.
6. NOTE: Position the Adapter so it does not contact the housing.
NOTE: Offset the Adapter to obtain an accurate reading.
Rotate the Adapter several half turns to seat the drive pinion bearings and position the Adapter as
shown.
7. Install the Drive Pinion Gauge Tube, the 2 bearing caps and the 4 bolts.
8. NOTE: Drive pinion bearing adjustment shims must be flat and clean.

NOTE: A slight drag should be felt for correct shim selection. Do not attempt to force the pinion
shim between the Adapter and the Gauge Tube. This will minimize selection of a pinion shim thicker
than required, which results in a deep tooth contact in the final assembly of integral rear axle
assemblies.
Use a drive pinion bearing adjustment shim as a gauge for shim selection.
9. Position the drive pinion bearing adjustment shim and the inner pinion bearing on the drive pinion
gear stem.
10. Using the Bearing/Oil Seal Plate and Drive Pinion Bearing Cone Installer and a suitable press, firmly
seat the drive pinion bearing adjustment shim and inner pinion bearing on the drive pinion gear stem.
11. NOTE: Make sure the splines on the drive pinion gear stem are free of burrs. If burrs are evident,
remove them using a fine crocus cloth.
Place a new differential drive pinion collapsible spacer on the drive pinion gear stem against the
pinion stem shoulder.

12. Install the outer pinion bearing and the drive pinion oil seal slinger.
13. NOTICE: Installation without the correct tool can result in early seal failure. If the rear axle
drive pinion seal becomes cocked during installation, remove it and install a new one.
NOTE: Coat the lips of the rear axle drive pinion seal with grease.
Place the drive pinion oil seal on the Drive Pinion Oil Seal Installer and drive the seal into place.
14. NOTE: Lubricate the pinion flange splines with rear axle lubricant.
Install the drive pinion gear with the differential drive pinion collapsible spacer in the differential
housing.
15. NOTE: Disregard the scribe marks if a new pinion flange is being installed.
Align the pinion flange with the drive pinion shaft.

16. With the drive pinion in the axle housing, install the pinion flange using the Drive Pinion Flange
Installer.
17. Position the new pinion nut.
18. NOTICE: Do not, under any circumstance, loosen the pinion nut to reduce drive pinion bearing
preload. If it is necessary to reduce drive pinion bearing preload, install a new differential drive
pinion collapsible spacer and pinion nut or damage to the component may occur.
NOTE: Remove the Drive Pinion Flange Holding Fixture while taking drive pinion bearing preload
readings with the Nm (lb-in) torque wrench.
Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, tighten the pinion nut.
Rotate the drive pinion gear occasionally to make sure the drive pinion bearings seat
correctly. Take frequent drive pinion bearing preload readings by rotating the drive pinion
gear with a Nm (lb-in) torque wrench.
19. Tighten the pinion nut to set the drive pinion bearing preload. Refer to the torque specification for
drive pinion bearings in the Specifications portion of this section.
20. Using the Differential Carrier Bearing Installer, press the left and right differential bearing on the
differential assembly.

21. Install the differential ring gear.

1. Place the differential ring gear on the differential assembly.
2. Hand-start 3 new ring gear bolts to align the holes in the differential ring gear and the
3. Place the differential assembly and differential ring gear onto the press bed blocks with the
differential ring gear teeth facing downward.
4. Press the differential ring gear into place.
22. Install the 12 new ring gear bolts.

23. Install the differential assembly in the following sequence.

1. Position the differential bearing cups on the differential bearings.
2. Lower the differential assembly in place.
Install a differential bearing shim of the thickness shown on the LH side of the differential case.
25. NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated.
Install the left bearing cap and loosely install the 2 bearing cap bolts.

Install progressively thicker differential bearing shims on the right side until the thickest differential
bearing shim can be inserted by hand.
27. Install the right bearing cap and 2 bolts.
28. Tighten the 4 differential bearing cap bolts.

29. Rotate the differential case to make sure it turns freely.
30. Adjust the ring gear backlash. For additional information, refer to Ring Gear Backlash Adjustment in
this section.


08/12/2010
Differential Bearings
Special Tool(s)
2 Jaw Puller
Adapter f05-S127
205-111 (T76P-4020-A11)

205-159 (T80T-4020-F42)

205-160 (T80T-4020-F43)

205-226 (T85T-4020-AH1)

205-383 (T97T-4020-B)

205-377 (T97T-4020-A)

205-126 (T78P-4851-A)

307-003 (T57L-500-B)


205-488

205-024 (T67P-4616-A)

205-233 (T85T-4851-AH)
Differential Bearings 2004


205-208 (T83T-4676-A)

205-387 (T97T-4628-A)

205-852

205-090 (T75L-1165-B)

205-229 (T85T-4209-AH)
Puller, Bearing
Step Plate
Material
Item Specification
XG-1-C or XG-1-K (US); CXG-1-C
(Canada)

1 390919-S101 Differential housing cover bolt (12 required)


3 - Differential bearing cap bolts (part of 4010) (4
required)
4 - Differential bearing caps (part of 4010) (2 required)
5 4067 Differential bearing shims
6 4222 Differential bearing cups
7 4221 Differential bearings
8 4204 Differential assembly
9 - Differential pinion gear (part of 4209)
14 4010 Differential housing
15 4616 Outer drive pinion bearing cup
16 4621 Outer drive pinion bearing
18 4676 Driion oil seal
Removal
3. Remove the 12 differential housing cover bolts.


be visible. Always install the differential bearing caps in their identical locations and positions
Remove the differential assembly.
Position wood blocks at the top and bottom of the differential assembly.
Pry the differential assembly and the differential bearing shims out of the differential housing.
7. Using the 2 Jaw Puller and Step Plate, remove the differential bearing.
8. Using the Drive Pinion Flange Holding Fixture, hold the pinion flange to remove and discard the
pinion nut.

10. Use a screwdriver to force up the metal flange of the drive pinion oil seal. Install gripping pliers and
strike with a hammer to remove the drive pinion oil seal.
11. Remove the drive pinion oil seal deflector, drive pinion oil seal slinger and the outer pinion bearing.
Discard the outer drive pinion bearing.
12. Using the Drive Pinion Thread Protector and a soft-faced hammer, remove the differential pinion gear
from the differential housing.

14. Using the Bearing Puller and a suitable shop press, remove and discard the inner drive pinion bearing.
bearing.
Installation
1. Position the Drive Pinion Bearing Cup Installer, Rear Axle Pinion Bearing Cup Installers and the
inner and outer drive pinion bearing cups in their respective bores.
1. Place the Rear Axle Pinion Bearing Cup Installer on the outer drive pinion bearing cup.
2. Place the Rear Axle Pinion Bearing Cup Installer on the inner drive pinion bearing cup.

2. Tighten the Drive Pinion Bearing Cup Installer to fully seat the differential drive pinion bearing.
Install the new drive pinion bearings, Drive Pinion Depth Gauge/Aligner, Drive Pinion Gauge Tube,
Drive Pinion Depth Gauge/Aligner and Adapters as shown.


2 205-160 Adapter for 205-S127
5 205-159 Adapter for 205-S127
8 4010 Rear axle housing outer (front) pinion bearing
9 205-111 Adapter for 205-S127
5. NOTE: This step duplicates drive pinion bearing preload.
Rotate the Adapter several half turns to seat the drive pinion bearings. Position the Adapter as shown.
7. Install the Drive Pinion Gauge Tube, the 2 bearing caps and the 4 bolts.
8. Use a drive pinion bearing adjustment shim as a gauge for shim selection. Check the drive pinion
bearing adjustment shim thickness between the Adapter and the gauge tube. A slight drag indicates
correct shim selection.

gear stem.
10. Using the Bearing/Oil Seal Plate and Drive Pinion Bearing Cone Installer and a suitable press, firmly
seat the drive pinion bearing adjustment shim and inner pinion bearing on the drive pinion gear stem.
Place a new differential drive pinion collapsible spacer on the drive pinion gear stem against the
pinion stem shoulder.

drive pinion seal.
NOTE: Coat the drive pinion seal lips with long-life grease.
Using the Drive Pinion Oil Seal Installer, install the new drive pinion seal.
14. Install the drive pinion gear with the differential drive pinion collapsible spacer in the differential
housing.
15. Align the pinion flange to the pinion index marks.
16. Using the Drive Pinion Flange Installer, install the pinion flange.

Use the Drive Pinion Flange Holding Fixture to hold the pinion flange while tightening the pinion nut.
19. Using the Differential Carrier Bearing Installer, press the left and right differential bearing on the
20. Install the differential assembly in the following sequence.

1. Position the 2 differential bearing cups on the differential bearings.
2. Lower the differential assembly in place.
Install a differential bearing shim of the thickness shown on the LH side of the differential case.


26. Rotate the differential case to make sure it turns freely.
this section.


Axle
Special Tool(s)
2 Jaw Puller

205-111 (T76P-4021)

205-159 (T80T-4020-F42)

205-160 (T80T-4020-F43)

205-226 (T85T-4020-AH1)

205-383 (T97T-4020-B)
Dial Indicator Gauge With Holding Fixture

100-002 (TOOL-4201-C)

308-021 (T75L-4201-A)
Gauge, Differential (Traction Lock)

205-384 (T97T-4205-A)
Gauge, Differential (Traction Lock)

205-386 (T97T-4205-D)

205-377 (T97T-4020-A)

205-126 (T78P-4851-A)

307-003 (T57L-500-B)
Axle 2017

205-D044 (D81T-4221-A)
Installer, Drive Pinion Bearing

205-488

205-024 (T67P-4616-A)

205-233 (T85T-4851-AH)

205-208 (T83T-4676-A)

205-852

205-387 (T97T-4628-A)

205-090 (T75L-1165-B)

205-229 (T85T-4209-AH)
Puller, Bearing
205-D064 (D84L-1123-A)
Rotator, Differential
205-378 (T97T-4205-C)
Step Plate
205-D019 (D80L-630-8) or equivalent
Material
Item Specification
Additive Friction Modifier EST-M2C118-A
XL-3 (US); CXL-3 (Canada)
Synthetic Rear Axle Luricant and GL-5
XY-75W140-QL (US);
CXG-1-C (Canada)
Axle 2018
Part
1 4067 Differential bearing shim
2 4222 Differential bearing cup
3 4204 Differential case
4 4216 Differential ring gear bolt
5 4230 Differential pinion gear thrust
washer
6 4211 Differential pinion shaft
7 4241 Differential pinion shaft lock
bolt
8 - Differential ring gear (part of
4209)
9 4221 Differential bearing
11 4B416 Inboard CV joint stub shaft
pilot bearing housing seal
12 4B413 Inboard CV joint stub shaft
pilot bearing
14 4662 Differential drive pinion 15 4670 Drive pinion
collapsible spacer shaft oil slinger
16 4851 Pinion flange
17 4320 Pinion nut
18 4859 Drive pinion oil seal deflector
19 4676 Drive pinion seal
20 4621 Drive pinion bearing
21 4616
Axle 2019
Differential drive pinion

bearing cup
22 56187-S Differential bearing cap bolt
23 - Drive pinion gear (part of
4209)
24 - Differential bearing cap (part
of 4010)
25 4628 Drive pinion bearing cup
adjustment shim
28 4228 Differential side gear thrust
washer
29 4236 Differential side gear
30 4215 Differential pinion gear
31 390943 Fill plug
Traction-Lok
33 4947 Differential clutch pack
34 - Steel plate (part of 4947)
35 - Friction plate (part of 4947)
36 - Shim (part of 4947)
37 - Belleville spring (part of 4947)
38 - Thrust ential case (part of
4204)
Disassembly
All axles
1. Remove the axle assembly from the vehicle. For additional information, refer to Axle Assembly in
this section.
3. Remove and discard the 12 bolts and the differential housing cover.
Axle 2020
5. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, measure and record
the differential ring gear backlash between teeth in 4 equally spaced places around the ring gear.
Remove the Dial Indicator Gauge.
damage to the components may occur.
NOTE: Tag the bearing caps and shims for location as removed.
Position wood blocks at the top and bottom of the differential assembly and pry the differential
assembly and the differential bearing shims out of the differential housing.
Excessive differential ring gear backlash between teeth
NOTE: If the differential ring gear backlash between teeth measurement, taken at the beginning of this
procedure, did not exceed the specification, proceed to Final disassembly in this procedure. If the differential
ring gear backlash between teeth measurement exceeds the specification, the cause may be a warped
Axle 2021
differential ring gear, a damaged differential case or loss of differential bearing preload. Verify the cause of
the excessive runout.
8. Remove and discard the 12 differential ring gear bolts.
9. NOTICE: Do not damage the bolt hole threads.
Insert a punch in the bolt holes and drive off the differential ring gear.
10. NOTE: Visually inspect the differential carrier bearings and cups for discoloration or other signs of
bearing failure.
NOTE: Install the differential bearing cups and shims in the same locations they were in before
disassembly.
Install the differential case. Rotate the differential case to seat the differential bearings.
11. Using the Dial Indicator Gauge with Holding Fixture, measure the differential case flange runout.
1. Rotate the differential case to make sure the differential bearings are seated.
2. Position the Dial Indicator Gauge with Holding Fixture.
If the runout does not exceed the specification, the cause of the original excessive runout is
the differential ring gear. Remove the differential case. Discard the differential ring gear and
the drive pinion gear. Proceed to Final disassembly in this procedure.
If the runout exceeds the specification, the differential ring gear is true and the concern is due
to either differential case/differential bearing damage.
Remove the Dial Indicator Gauge with Holding Fixture.
Axle 2022
12. Remove the differential case from the rear axle housing, and remove the differential bearings using
the 2 Jaw Puller and Step Plate.
13. Using the Differential Carrier Bearing Installer, install the new differential bearings on the differential
case.
14. Using the Dial Indicator Gauge with Holding Fixture, measure the differential case runout without the
differential ring gear.
Check the differential case flange runout again with the new differential bearings. If the
runout is now within the specification shown, use the new differential bearings for assembly.
If the runout is still excessive, the differential case is damaged and must be installed new.
Final disassembly, differential case and ring gear - Traction-Lok
Axle 2023
Insert a punch in the bolt holes and drive the differential ring gear off the differential case.
17. NOTE: The differential bearings do not need to be removed to overhaul the Traction-Lok differential.
Remove and discard the differential pinion shaft lock bolt and remove the differential pinion shaft.
18. Install the Differential Gauge in a suitable vise.
19. Install the differential case on the Differential Gauge.
20. NOTE: Apply a small amount of grease to the centering hole of the Differential Gauge.
Install the Differential Gauge in the bottom side gear bore.
21. Install the nut in the upper differential side gear. Hold the nut in position while installing the hex
screw. Tighten the hex nut until contact is made with the Step Plate.
Axle 2024
22. NOTE: The dowel bar is used to keep the nut from turning when the forcing screw is tightened.
Insert a suitable dowel bar in the hole of the nut. Tighten the forcing screw to force the differential
side gear away from the differential pinion gears.
23. Insert the Differential Rotator in the pinion shaft bore and turn the differential case to move the
differential pin gears and thrust washers to the differential case opening.
24. Remove the differential pinion gears and differential pinion gear thrust washers.
25. Remove the differential side gears and differential clutch packs. Tag the gears, clutch packs and shims
for location.
Axle 2025
26. NOTICE: When separating the clutch plates and clutch discs, note the sequence in which they
are disassembled. They must be reassembled in the same sequence or damage to the component
may occur.
NOTE: Do not use acids or solvents to clean the differential clutch components. Use a clean, lint-free
cloth only.
Separate the differential clutch packs for cleaning and inspection.
Final disassembly, differential case and ring gear - conventional
Insert a punch in the bolt holes and drive off the differential ring gear.
Axle 2026
29. Using the 2 Jaw Puller and Step Plate, remove the 2 differential bearings.
All axles
30. Record the torque necessary to maintain rotation of the drive pinion gear through several revolutions
prior to removing the drive pinion flange.
31. NOTICE: After removing the drive pinion nut, discard it. Use a new nut for installation or
Using the Drive Pinion Flange Holding Fixture, remove the drive pinion nut.
32. Index-mark the drive pinion flange and drive pinion gear stem to maintain initial balance during
installation.
33. Using the 2 Jaw Puller, remove the drive pinion flange.
34. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer
until the pinion seal is removed.
Axle 2027
35. Remove the drive pinion shaft oil slinger.
36. Using the Drive Pinion Thread Protector and a soft-faced hammer, drive the drive pinion gear out of
the front pinion bearing and remove it through the rear of the differential housing.
38. Using the Bearing Puller and a suitable press, remove the drive pinion bearing.
bearing.
Axle 2028
Assembly
Assembly, differential case and ring gear - Traction-Lok
1. Prelubricate each steel clutch plate and soak all friction plates with 118 ml (4 oz) of friction modifier
for at least 15 minutes.
2. NOTE: The concave side of the Belleville spring must face up and against the thrust face of the
differential case.
Place the shim and the Belleville spring on the differential clutch pack.
3. Insert the differential clutch packs with the shims and Belleville springs and differential side gears
into the differential case.
Axle 2029
4. NOTE: If necessary, insert the dowel bar in the nut bore to keep the nut from turning as the hex
screw is tightened.
Assemble the Differential Gauge in the differential case.
1. Position the Differential Gauge in the bottom side gear bore.

Position the Differential Gauge in the top side gear bore and hold it in place.
3. Install the Differential Gauge and tighten it 2 turns after it contacts the bottom step plate.
5. NOTE: Coat both sides of the differential pinion thrust washers with rear axle lubricant.
Position the differential pinion gears and thrust washers in the differential case window so they mesh
with the differential side gear teeth.
6. NOTE: It may be necessary to loosen or tighten the Differential Gauge forcing screw to allow the
differential side gears to rotate.
Insert the Differential Gauge into the pinion shaft bore and turn the differential case. This will move
the differential side gears and position them in the differential case. Rotate the differential case until
the pinion mating shaft holes are aligned with the differential pinion gears.
7. Loosen the Differential Gauge forcing screw and remove the Differential Gauge from the differential
case. Install a new differential pinion shaft and bolt in the differential case.
Axle 2030
8. If removed, install new differential carrier bearings.
9. Using the Differential Gauge, check the torque required to rotate on differential side gear.
Install the Differential Gauge as shown.
If the original clutch plates are used, the initial breakaway torque must be within
specification. The rotating torque required to turn the differential side gear with new clutch
plates, may vary.

1. Place the differential ring gear on the differential case.
2. Hand-start 3 new bolts to align the ring gear to the differential case.
3. Place the differential case and ring gear on the press bed with the ring gear teeth facing down.
4. Press the ring gear into place on the differential case.
11. Install the 9 remaining new ring gear bolts.

Tighten alternately and evenly to 150 Nm (111 lb-ft).
Assembly, differential case and ring gear - conventional
12. NOTE: Coat the differential side gears and differential side gear thrust washers with rear axle
lubricant.
Position the differential thrust washers on the differential side gears.
Axle 2031
13. Position the differential side gears and thrust washers in the differential case.
14. NOTE: Coat the differential pinion thrust washers and differential pinion gears with rear axle
lubricant.
Assemble the differential pinion thrust washers and the differential pinion gears.
15. Engage the differential pinion gears opposite the differential side gears.
16. Rotate the differential pinion gears to align with the differential pinion shaft bore.
17. Insert the differential pinion shaft.
Axle 2032
18. Install a new differential shaft lock bolt.

19. Using the Differential Carrier Bearing Installer, install the differential bearings.

1. Place the differential ring gear on the differential case.
2. Hand-start 3 bolts to align the holes in the differential ring gear and the differential case.
3. Place the differential case and the differential ring gear on the press bed with the ring gear
facing down.
4. Press the ring gear into place.
21. Install the 9 remaining new differential ring gear bolts.

Tighten alternately and evenly to 150 Nm (111 lb-ft).
Final assembly - all differentials
Axle 2033
22. Position the inner and outer bearing cups in their respective bores.
1. After positioning the bearing cups in the bores, place the Rear Axle Pinion Bearing Cup
Installer on the inner bearing cup.
2. Place the Rear Axle Pinion Bearing Cup Installer on the outer bearing cup.
23. Tighten the Drive Pinion Bearing Cup Installer to seat the bearing cups in the bores.
25. NOTE: Apply a light film of axle lubricant on the front and rear pinion bearings.
Install the pinion bearings and Drive Pinion Depth Gauge/Aligner, Drive Pinion Gauge Tube, Drive
Pinion Depth Gauge/Aligner and Adapters as shown.
Axle 2034

2 205-160 Adapter for 205-S127
5 205-159 Adapter for 205-S126
8 4010 Rear axle housing
9 205-111 Adapter for 205-S127
26. NOTE: This step duplicates pinion bearing preload.
Rotate the Adapter several half turns to seat the drive pinion bearings and position the Adapter as
shown.
28. Install the Drive Pinion Gauge Tube, 2 bearing caps and 4 bolts.
Axle 2035
NOTE: A slight drag should be felt for correct shim selection. Do not attempt to force the pinion
shim between the Adapter and the Gauge Tube. This will minimize selection of a pinion shim thicker
than required, which results in a deep tooth contact in the final assembly of integral rear axle
assemblies.
gear stem.
31. Using the Bearing/Oil Seal Plate and Drive Pinion Bearing Installer, press the inner pinion bearing
and pinion shim until they are firmly seated on the pinion.
Place a new drive pinion collapsible spacer on the pinion shaft against the pinion stem shoulder.
Axle 2036
34. NOTICE: Installation without the correct tool can result in early seal failure. If the rear axle
drive pinion seal becomes cocked during installation, remove it and install a new one.
NOTE: Coat the lips of the rear axle drive pinion seal with grease.
Place the drive pinion oil seal on the Drive Pinion Oil Seal Installer and drive the seal into place.
35. NOTE: Lubricate the pinion flange splines with rear axle lubricant.
Install the drive pinion in the drive pinion carrier bore from inside the rear axle housing. Seat the
drive pinion with a plastic hammer.
36. NOTE: Disregard the scribe marks if a new pinion flange is being installed.
Align the pinion flange with the drive pinion shaft.
37. With the drive pinion in the axle housing, install the pinion flange using the Drive Pinion Flange
Installer.
Axle 2037
38. Position the new pinion nut.
Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, tighten the pinion nut.
41. With the pinion depth set and the pinion installed, place the differential case in the rear axle housing.
Install a shim as shown on the left side.
Axle 2038
43. NOTE: Apply pressure toward the left side to make sure the left bearing cup is seated.
44. Install progressively larger shims on the right side until the largest shim selected can be installed by
hand.
45. Install the right side bearing cap and tighten the 2 bolts.
46. Rotate the differential case to make sure it rotates freely.
this section.
Axle 2039
Axle 2040
SECTION 205-03: Front Drive Axle/Differential 2011 Expedition, Navigator Workshop Manual
Material

Capacity
Motorcraft High Contrast - -
Hypoid Gear Marking
Compound
XG-14
Motorcraft SAE 80W-90 WSP-M2C197-A 1.70L
Premium Rear Axle Lubricant (3.6 pt)
XY-80W90-QL (US);
Premium Long-Life Grease ESA-M1C75-B -
CXG-1-C (Canada)
TA-30
TA-25
Item Specification
Backlash Specifications
Ring gear backlash 0.204-0.305 mm (0.008-0.012 in)
Ring gear maximum backlash between teeth 0.101mm (0.004 in)
Clearance Specifications
Differential case maximum runout 0.076 mm (0.003 in)
Housing spreader adapter thread engagement 12.5 mm (0.500 in)
Maximum differential housing spread 0.762 mm (0.030 in)
Lubricant Fill Level Checks
Front axle
Lubricant level 38 in) below bottom of differential housing fill hole
Rotational Torque Ranges
Pinion bearing torque preload 1.8-3.3 Nm (16-29 lb-in)
Axle housing bushing bolts 150 111
Axle 2041
Axle housing tube bolts 73 54

Crossmember bolts and nuts 90 66
Differential bearing cap bolts 105 77
Differential housing cover bolts 32 24
Differential pinion shaft lock bolt 30 22
Fill plug 25 18
Ring gear bolts a - -
Steering column shaft bolt 30 22
Axle 2042
Front Drive Axle and Differential
The front drive axle consists of:
a cast-aluminum center section, a removable cast-aluminum axle housing tube and a differential
housing cover. Both the axle housing tube and the differential housing cover use silicone sealant as a
gasket.
a hypoid-design gearset of an 8.8-inch ring gear and a pinion gear. Two opposed tapered roller
bearings support the drive pinion in the axle housing.
a drive pinion collapsible spacer, located on the pinion shaft, maintains pinion bearing preload. The
pinion nut adjusts the preload.
differential bearing shims, located between the differential bearing cups and the axle housing, adjust
the differential bearing preload and the ring gear backlash.
a differential case, a 1-piece design with 2 openings to allow for assembly of the internal components
and lubricant flow. Two opposed tapered roller bearings (differential bearings) support the differential
case in the axle housing. Removable differential bearing caps retain the differential assembly in the
axle housing.
inside the differential case, the differential pinion shaft supports 2 differential pinion gears. The
pinion gear speed is synchronized by a differential clutch spring. The pinion gears engage the
differential side gears, to which the left axle shaft and the right axle shaft are splined. The differential
pinion shaft bolt retains the differential pinion shaft in the differential case.
an embossed metal tag, bolted to the rear face of the RH axle tube, contains front axle identification
information.
The front drive axle receives input from the transfer case by way of the front driveshaft. Rotational torque is
transferred through the drive pinion to the ring gear, which in turn drives the differential case. Inside the
differential case are the pinion gears which rotate on the stationary pinion shaft and the side gears which are
splined to the axle shafts. The differential assembly is a gear arrangement that allows the drive wheels to be
driven at different speeds and divides the input torque of the pinion gear between the axle halfshafts. The front
axle transmits torque only and carries no vehicle load. CV joints located at each end of the halfshafts allow the
axle to remain stationary in relationship to front wheels, yet articulate at the knuckle. These CV joints permit
the wheels to be driven and turned at the same time. Lack of lubrication is among the most common causes of
CV joint concerns. It is essential that all CV boots and clamps be inspected for damage or signs of leakage.
Front Drive Axle and Differential 2043

Front Drive Axle and Differential 2044

Front Drive Axle
Front Drive Axle 2045

Differential Case Runout Check
Special Tool(s)
2 Jaw Puller
Dial Indicator Gauge With Holding Fixture

100-002 (TOOL-4201-C)
Installer, Differential Side Bearing

205-010 (T57L-4221-A2)
Spreader, Differential Carrier

205-001 (TOOL-4000-E)
Step Plate
205-D061 (D83T-4205-C2)
1. Remove the differential carrier. For additional information, refer to Differential Carrier in this section.
2. NOTE: Use a drift punch to separate the ring gear from the differential case.
Remove and discard the 10 bolts. Remove the ring gear.
3. NOTE: Visually inspect the differential bearing cups and cones for discoloration indicating bearing
overheating or failure.
NOTE: It may be necessary to use the Differential Carrier Spreader to carry out this step.
Install the differential case with the bearing cups and all the shims in the housing.
1. Position the differential case with the bearing cups and shims in their original location.
2. Install the 2 bearing caps.
3. Install the 4 bolts.
4. Rotate the differential case to make sure the bearings have seated correctly.
Differential Case Runout Check 2046

5. Rotate the differential case and check the differential case runout using the Dial Indicator Gauge with
Holding Fixture.
If the runout does not exceed the specification, install a new ring gear and pinion.
If runout exceeds the specification, the ring gear is true and the condition is due to differential
case/differential bearing damage.
Inspect the differential bearings and the differential case. Always install new
differential bearings when installing a new differential case, or if a bearing condition
is questionable.
6. Remove the bearing caps and the differential case with the bearing cups and shims from the housing.
7. If necessary, using the 2 Jaw Puller and Step Plate, remove the differential bearings.
8. NOTICE: Press against the differential bearing inner cone only or damage to the component
may occur.

Install the new differential bearings.
1. Position the appropriate differential bearing (RH or LH).

2. Using a suitable press and the Differential Side Bearing Installer, install the differential
bearing.
Repeat the steps for the other differential bearing.
9. NOTE: It may be necessary to use the Differential Carrier Spreader to carry out this step.
NOTE: Recheck the flange runout.
Install the differential case with the bearing cups and the shims in the housing.
1. Position the differential case with the bearing cups and shims in their original locations.
2. Install the 2 bearing caps.
4. Rotate the differential case to make sure the bearings have seated correctly.
11. NOTE: If the runout is still excessive, install a new differential case.
Using the Dial Indicator Gauge with Holding Fixture, check the runout with the new differential
bearings. If the runout does not exceed the specification, use the new differential bearings for
assembly.

13. Remove the differential case with the bearing cups and the shims from the housing.
1. Remove the 2 bearing caps.
2. Remove the differential case with the bearing cups and the shims from the housing.

3. Place the differential carrier and differential ring gear onto the press bed blocks with the


16. Install the differential carrier. For additional information, refer to Differential Carrier in this section.

Drive Pinion Flange and Seal
Special Tool(s)
2 Jaw Puller

205-126 (T78P-4851-A)

205-002 (TOOL-4858-E)

205-208 (T83P-4676-A)
Material
Item Specification
Motorcraft SAE 80W-90 WSP-M2C197-A
Premium Rear Axle Lubricant
XY-80W90-QL (US);

1 389546 Pinion nut and washer
2 4858 Pinion flange
3 3N134 Drive pinion oil seal
4 3C202 Axle housing
Removal
Drive Pinion Flange and Seal 2051

NOTICE: The color on the rear face of the drive pinion nut is critical to this repair. Use the same color
new drive pinion nut for installation as the original. If a new collapsible spacer must be installed for
pinion bearing preload reduction, install the nut supplied with the new spacer or damage to the
component may occur.
NOTICE: This operation disturbs the pinion bearing preload. Carefully reset the pinion bearing
preload during assembly.
100-02 .
2. Remove the front brake pads. For additional information, refer to Section 206-03 .
4. Measure and record the pinion bearing preload.

Using a Nm (lb-in) torque wrench, rotate the pinion gear. Measure the torque required to
maintain pinion gear rotation.
5. Index-mark the pinion flange and the drive pinion gear.
collapsible spacer. If a new collapsible spacer is installed, install the nut in the kit or damage to
the component may occur.
Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, remove and discard the
pinion nut and washer.

8. Inspect the pinion flange for burrs and damage. Inspect the end of the pinion flange that contacts the
pinion bearing cone, pinion nut counterbore and drive pinion seal surface for nicks. Discard the pinion
flange if damaged.
9. NOTICE: Do not damage the axle housing.
Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer
to remove the drive pinion seal.
10. Verify the splines on the drive pinion gear are free of burrs. If burrs are evident, remove them with a
fine crocus cloth.
11. Clean the drive pinion seal bore.
Installation
1. NOTE: Lubricate the drive pinion seal lips with axle lubricant.
NOTE: Drive pinion seal must be fully seated all the way around or drive pinion seal damage will
occur.
2. NOTICE: Never use a hammer or install the pinion flange with power tools.
NOTE: Lubricate the pinion flange splines with axle lubricant.
Align the index marks made during removal and, using the Drive Pinion Flange Installer, install the
pinion flange.

3. NOTICE: The color on the rear face of the drive pinion nut is critical to this repair. Use the
same color new drive pinion nut for installation as the original. If a new collapsible spacer must
be installed for pinion bearing preload reduction, install the nut supplied with the new spacer or
Select the correct pinion nut for installation.
8.8 In. Drive Pinion Nut
Part Number Color Description Part Description

389546-S100 Orange Pinion nut
4320 Purple Pinion nut
4C121 Purple Kit with spacer for all 223.52 mm (8.8
in) axles
collapsible spacer or damage to the component may occur.
Install the new washer and pinion nut. Only hand-tighten the pinion nut at this time.
5. NOTICE: Do not loosen the pinion nut to reduce drive pinion bearing preload. Install a new
drive pinion collapsible spacer and pinion nut if drive pinion bearing preload reduction is
necessary. If a new collapsible spacer must be installed for pinion bearing preload reduction,
install the nut supplied with the new spacer or damage to the component may occur.
Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, tighten the pinion nut to set
the drive pinion bearing preload.
Tighten the pinion nut, rotating the pinion occasionally to make sure the drive pinion bearings
are seating correctly. Take frequent drive pinion bearing preload readings by rotating the
drive pinion gear with a Nm (lb-in) torque wrench. The final reading must be 0.56 Nm (5
lb-in) more than the initial reading taken during removal.
6. Install the front driveshaft. For additional information, refer to Section 205-01 .
7. Install the disc brake pads. For additional information, refer to Section 206-03 .


Stub Shaft Pilot Bearing and Seal
Special Tool(s)
Handle
205-D055 (D81L-4000-A)
Installer, Axle Shaft Oil Seal

205-123 (T78P-1177-A)
Installer, Wheel Speed Sensor Ring

206-034 (T88P-20202-B)
Remover, Bearing Cup

308-047 (T77F-1102-A)
Remover, Transmission Fluid Pump

307-397
Slide Hammer
100-001 (T50T-100-A)

1 3A380 Intermediate shaft
2 3B112 Stub shaft seal
3 4B413 Stub shaft bearing
4 3B210 Axle housing tube
Removal
NOTE: Install a new stub shaft seal whenever a halfshaft is removed.

2. Using the Transmission Fluid Pump Remover and Slide Hammer, remove the intermediate shaft.
3. Remove and discard the intermediate shaft circlip.
4. Using a suitable seal remover, remove and discard the stub shaft pilot bearing oil seal.
5. Using the Bearing Cup Remover and Slide Hammer, remove and discard the stub shaft pilot bearing.
Installation
1. Position the stub shaft pilot bearing in the axle tube or differential housing bore and using the Axle
Shaft Oil Seal Installer, install the bearing.
2. Carefully align the stub shaft pilot bearing oil seal with the housing bore and install the stub shaft
bearing oil seal flush in the housing using the Wheel Speed Sensor Ring Installer and Handle.
3. Install a new circlip on the intermediate shaft end.

4. Insert the intermediate shaft and engage the circlip with the differential side gear.
5. Install the halfshafts. For additional information, refer to Section 205-04 .

Axle Assembly

1 W712724 Axle tube bushing bolt
2 W712723 Axle tube bushing flagnut
3 W712724 Rear axle housing bushing bolt
4 N808684 Steering column coupler bolt
5 W712743 Front axle housing bushing support bolt
6 636893 Crossmember nuts (4 required)
3. Remove the 4 crossmember nuts and bolts and the crossmember.

4. Use a high-lift jack to support the axle assembly.
Axle Assembly 2059

5. Remove the axle tube bushing bolt and flagnut.

6. Remove the front axle housing bushing bolt.

7. NOTE: Use a steering wheel holding device (such as a Hunter 28-75-1 or equivalent).
Using a suitable holding device, hold the steering wheel in the straight-ahead position.
8. NOTICE: Do not allow the steering column to rotate while the steering column shaft is
disconnected or damage to the clockspring may result. If there is evidence that the steering
column has rotated, the clockspring must be removed and recentered. For additional
information, refer to Section 501-20B .
Remove and discard the steering column shaft-to-steering gear bolt and disconnect the shaft from the
steering gear.
Axle Assembly 2060

9. Remove the rear axle housing bushing bolt.

10. Carefully lower the front drive axle assembly.
11. Disconnect the vent hose from the axle vent barbed fitting.
12. NOTE: Make sure the axle vent hose is connected.
Axle Assembly 2061

Axle Carrier Bushing
Special Tool(s)
Installer, Front Axle Mounting Bushing

Drawbolt
205-374 (T96T-5638-H)
Installer, Front Differential Mounting
Bushing
204-187 (T95T-5638-AH)
Installer, Wheel Hub Dust Seal
205-289 (T89P-1249-A)
Remover, Front Axle Mounting Bushing

Cup
205-371 (T96T-5638-E)
Remover, Front Axle Mounting Bushing
205-376 (T96T-5638-K)
Remover, Front Differential Housing

Bushing
204-186 (T95T-5638-AH)
Remover/Installer, Front Differential
Housing Bushing
205-527/1

1 W712724 Axle bushing bolts (2 required)
2 5638 Axle bushings (3 required)
3 W712723 Axle bushing flagnut
4 W712743 Axle bushing bolt
Removal
Axle Carrier Bushing 2062

All bushings
1. NOTE: It is not necessary to remove the axle assembly from the jack.
Remove the axle assembly. For additional information, refer to Axle Assembly in this section.
2. Measure and record the width of the gap between the bushing front lip and the housing. Mark the
housing at the point where the measurement was taken.
Axle tube bushing
3. Position the Front Axle Mounting Bushing Cup Remover, Front Differential Housing Bushing
Remover/Installer and Front Axle Mounting Bushing Drawbolt Installer as shown. Turn in the
drawbar to remove the bushing.
Rear housing bushing
4. Position the Front Differential Housing Bushing Remover, Front Axle Mounting Bushing Cup
Remover, Front Differential Housing Bushing Remover/Installer and Front Axle Mounting Bushing
Drawbolt Installer as shown. Turn in the drawbar to remove the bushing.
Front housing bushing
5. Remove the pinion flange. For additional information, refer to Drive Pinion Flange and Seal in this
section.
6. Position the Front Axle Mounting Bushing Cup Remover, Front Differential Housing Bushing
Remover/Installer and Front Axle Mounting Bushing Drawbolt Installer as shown. Turn in the
drawbar to remove the bushing.

All bushings
7. Inspect the bushing bores for wear or damage.
Installation
Axle tube bushing
1. Position the bushing and the Front Axle Mounting Bushing Remover, Front Differential Mounting
Bushing Installer, Front Axle Mounting Bushing Cup Remover and Front Axle Mounting Bushing
Drawbolt Installer as shown. Draw the bushing into the bushing bore to the same depth and point
measured before removal.
Rear housing bushing
2. Position the bushing and the Front Axle Mounting Bushing Remover, Front Differential Mounting
Bushing Installer, Front Axle Mounting Bushing Cup Remover and Front Axle Mounting Bushing
Drawbolt Installer as shown. Draw the bushing into the bushing bore to the same depth and point
measured before removal.
Front housing bushing
3. Position the bushing and the Front Differential Housing Bushing Remover/Installer, Wheel Hub Dust
Seal Installer, Front Differential Housing Bushing Remover, Front Differential Mounting Bushing
Installer and Front Axle Mounting Bushing Drawbolt Installer as shown. Draw the bushing into the
bushing bore to the same depth and point measured before removal.

4. Install the U-joint flange. For additional information, refer to Drive Pinion Flange and Seal in this
section.
All bushings
5. Install the axle assembly. For additional information, refer to Axle Assembly in this section.

Differential Ring And Pinion
Special Tool(s)
2 Jaw Puller

205-105 (T76P-4020-A3)

205-109 (T76P-4020-A9)

205-110 (T76P-4020-A10)

205-111 (T76P-4020-A11)

205-129 (T79P-4020-A18)
Adapter for Differential Housing Spreader

205-368 (T96T-4000-A)

100-002 (TOOL-4201-C)

308-021 (T75L-4201-A)

205-336 (T93P-4020-A)

205-126 (T78P-4851-A)

307-003 (T57L-500-B)
Installer, Differential Carrier Bearings



205-010 (T57L-4221-A2)

205-005 (T53T-4621-C)

205-024 (T67P-4616-A)

205-002 (TOOL-4858-E)

205-208 (T83P-4676-A)

205-460

308-047 (T77F-1102-A)

307-397
Slide Hammer
100-001 (T50T-100-A)

205-001 (TOOL-4000-E)
Spreader, Differential Housing (Plate)

205-335 (T93P-4000-A) (RH)
Step Plate
Material
Item Specification
XG-14
XY-80W90-QL (US);
CXG-1-C (Canada)


TA-30

1 390919 Differential housing cover bolt (10
required)
2 3N136 Differential housing cover
3 - Differential bearing cap bolt (part of
3A412) (4 required)
4 - Differential bearing cap (part of 3A412)
(2 required)
5 3C202 Differential assembly
6 388056 Ring gear bolt (10 required)
7 4221 Differential bearings (2 required)
8 4221 Differential bearing cups (2 required)
9 4A451 Differential bearing shims (2 required)
10 - Ring gear (part of 4209)
10 - Pinion gear (part of 4209)
Drive pinion bearing
4663
adjustment shim
15 3A380 Intermediate axle shaft
16 3A412 Differential housing

17 4631 Drive pinion oil baffle

18 4616 Drive pinion outer bearing cup
19 4621 Drive pinion outer bearing
23 389546 Drive pinion nut and washer
Removal
1. Remove the axle assembly. For additional information, refer to Axle Assembly in this section.

Drain the fluid.
3. NOTICE: The fixture mounting bolts must have the minimum specified thread engagement in
the carrier or damage to the component may occur.
Install the Transmission Holding Fixture.
5. Remove the 4 bolts and the axle housing tube.

6. NOTICE: The housing spreader adapter bolts must have the minimum specified thread
engagement in the carrier or damage to the component may occur.
Install the Adapter for Differential Housing Spreader and Differential Housing Spreader Plate.
7. Install the Dial Indicator Gauge with Holding Fixture, Clutch Housing Gauge and Differential Carrier
Spreader.
Position the adapter tip in the spreader adapter hole.
8. NOTICE: Overspreading may damage the axle housing.
Spread the axle housing to the specification.
1. Adjust the Dial Indicator Gauge to zero.

2. Tighten the housing spreader screw to spread the axle housing to the specification.
3. Remove the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.
9. NOTICE: Mark the differential bearing caps Top or Bottom and LH or RH appropriately
before removing them. Always install the bearing caps in their original location and position or
Mark and remove the 2 differential bearing caps.

2. Remove the 2 differential bearing caps.

10. NOTICE: Use wood blocks to avoid axle housing damage.
Remove the differential assembly from the axle housing.
1. Position the wood blocks.

2. Position and push down on the 2 pry bars.
3. Remove the differential assembly.
4. Remove the Differential Carrier/Spreader.
11. Install the Drive Pinion Flange Holding Fixture and loosen, but do not remove, the pinion nut.
12. With the pinion nut still engaged by a few threads, use the 2 Jaw Puller to separate the axle U-joint
flange from the pinion gear.
13. Remove the nut and the flange.
14. Using the Drive Pinion Thread Protector and a soft hammer, remove the pinion gear.

15. Discard the drive pinion collapsible spacer.
16. NOTICE: Do not damage the carrier housing while removing the pinion seal.
Remove the pinion seal and slinger.
Pry up on the seal flange. Install gripping pliers and strike with a hammer to remove the seal.
17. Remove the outer pinion bearing.
18. Using the Bearing Cup Remover and Slide Hammer, remove the inner pinion bearing cup.
19. NOTE: The pinion bearing oil baffle aids in bearing lubrication. Normally, it is not necessary to
remove the baffle.
If necessary, remove the pinion bearing oil baffle.
20. Remove the outer pinion bearing cup by tapping alternately on each side to prevent the cup from
cocking.

21. NOTE: Use a drift punch to separate the differential ring gear from the differential case.
Remove and discard the 10 differential ring gear bolts and remove the differential ring gear.
22. Using the 2 Jaw Puller and Step Plate, remove the 2 differential bearings.
Installation
1. NOTICE: Do not omit the drive pinion bearing oil baffle or damage to the component may
occur.
If removed, position the drive pinion bearing oil baffle on the Differential Carrier Bearings Installer.
2. Using the Differential Carrier Bearings Installer, install the drive pinion bearing oil baffle.
3. Using the Drive Pinion Bearing Cup Installer, install the drive pinion bearing cups.

Assemble and position the Adapters.

1 205-109 Adapter for 205-S127 (T76P-4020-A9)
2 205-105 Adapter for 205-S127 (T76P-4020-A3)
3 4630 Drive pinion bearing (inner)
4 205-129 Adapter for 105-S127 (T79P-4020-A18)
5 205-110 Adapter for 205-S127 (T76P-4020-A10)
6 4621 Drive pinion bearing (outer)
7 205-111 Adapter for 205-S127 (T76P-4020-A11)
5. NOTE: This step duplicates final drive pinion bearing preload.
Tighten the Adapter.
Tighten to 2.2 Nm (20 lb-in).

6. NOTE: The Adapter must be offset to obtain an accurate reading.
Rotate the Adapter several half-turns to make sure of correct seating of the drive pinion bearings and
position the Adapter.
7. Install the Drive Pinion Gauge Tube.

1. Position the Drive Pinion Gauge Tube.
2. Install the 2 differential bearing caps.
3. Install the 4 differential bearing cap bolts.
NOTE: A slight drag should be felt for correct drive pinion bearing adjustment shim selection. Do
not attempt to force the drive pinion bearing adjustment shim between the gauge block and the gauge
tube. This will minimize selection of a drive pinion bearing adjustment shim thicker than required,
which results in a deep tooth contact in final assembly of integral axle assemblies.
Use a drive pinion bearing adjustment shim as a gauge for drive pinion bearing adjustment shim
selection.
After the correct drive pinion bearing adjustment shim thickness has been determined,
remove all of the special tools.
9. Position the drive pinion bearing adjustment shim and the inner pinion bearing on the new drive
pinion gear stem.

10. NOTE: The same drive pinion bearings from the previous steps must be used.
Install the inner drive pinion bearing.
Place the drive pinion bearing adjustment shim on the drive pinion gear.
Using a suitable press and the Drive Pinion Bearing Cone Installer, press the inner drive
pinion bearing until it is firmly seated on the pinion gear.
11. Place a new drive pinion collapsible spacer on the drive pinion gear.
12. Install the outer drive pinion bearing.
13. Install the drive pinion oil slinger.
14. NOTE: Coat the drive pinion seal lips with long-life grease.
Install the drive pinion seal on the Drive Pinion Oil Seal Installer.

drive pinion seal.
16. Lightly lubricate the drive pinion gear splines with axle lubricant.
17. Position the drive pinion gear in the axle housing.
18. Position the pinion flange onto the pinion shaft while mounted on the Transmission Holding Fixture.
20. Apply a small amount of axle lubricant to the washer side of the new pinion nut and install the new
pinion nut.
21. NOTICE: Do not loosen the pinion nut to reduce drive pinion bearing preload under any
circumstance. If it is necessary to reduce drive pinion bearing preload, install a new drive
Install the Drive Pinion Flange Holding Fixture and tighten the pinion nut. For additional information,
refer to the torque specifications in the Specifications portion of this section.

Rotate the drive pinion gear occasionally to make sure the drive pinion bearings are seating
22. Press the left and right differential bearing on the differential carrier.
1. Position the differential bearing.
2. Using the Differential Side Bearing Installer, press the differential bearing on the differential
carrier.



25. Install the differential carrier.

2. Lower the differential carrier in place.
26. Install a differential bearing shim of the thickness shown on the LH side of the differential bearing.
27. NOTE: Apply pressure toward the left side to make sure the left bearing cup is seated.

31. Rotate the differential carrier to make sure it turns freely.
32. Install the Dial Indicator Gauge with Holding Fixture at the 12 o'clock position.
differential ring gear backlash at 4 equally spaced points.
1. Attach the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.
2. Position the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge tip
centrally on a drive tooth.
3. Zero the Dial Indicator.
4. Turn the differential ring gear without turning the drive pinion gear. Record the indicator
reading. The allowable backlash is 0.203 mm (0.008 in) to 0.305 mm (0.012 in) and must not
vary more than 0.101 mm (0.004 in) between points measured. A backlash variation of more
than 0.101 mm (0.004 in) between points checked indicates gear/case runout.
Backlash Thickness
Change Change
Required Required
mm Inch mm Inch
0.025 0.001 0.050 0.002
0.050 0.002 0.050 0.002
0.076 0.003 0.101 0.004
0.101 0.004 0.152 0.006

0.127 0.005 0.152 0.006

0.152 0.006 0.203 0.008
0.177 0.007 0.254 0.010
0.203 0.008 0.254 0.010
0.228 0.009 0.304 0.012
0.254 0.010 0.355 0.014
0.279 0.011 0.355 0.014
0.304 0.012 0.406 0.016
0.330 0.013 0.457 0.018
0.335 0.014 0.457 0.018
0.381 0.015 0.508 0.020
Differential Shim Size Chart - 4067
Dimension A
Numbers of Stripes and Color Code mm Inch
2 - C-COAL 7.7978- 7.8105 0.3070- 0.3075
1 - C-COAL 7.7470- 7.7597 0.3050- 0.3055
5 - BLU 7.6962- 7.7089 0.3030- 0.3035
4 - BLU 7.6454- 7.6581 0.3010- 0.3015
3 - BLU 7.5946- 7.6073 0.2990- 0.2995
2 - BLU 7.5458- 7.5565 0.2970- 0.2975
1 - BLU 7.493- 7.505 0.2950- 0.2955
5 - PINK 7.4422- 7.4549 0.2930- 0.2935
4 - PINK 7.3914- 7.4041 0.2910- 0.2915
3 - PINK 7.3406- 7.3533 0.2890- 0.2895
2 - PINK 7.2898- 7.3025 0.2870- 0.2875
1 - PINK 7.2390- 7.2517 0.2850- 0.2855
5 - GRN 7.1882- 7.2009 0.2830- 0.2835
4 - GRN 7.1374- 7.1501 0.2810- 0.2815
3 - GRN 7.0866- 7.0993 0.2790- 0.2795
2 - GRN 7.0358- 7.0485 0.2770- 0.2775
1 - GRN 6.9850- 7.0485 0.2750- 0.2755
5 - WH 6.9342- 6.9469 0.2730- 0.2735
4 - WH 6.8834- 6.8961 0.2710- 0.2715
3 - WH 6.8326- 6.8453 0.2690- 0.2695
2 - WH 6.7818- 6.7945 0.2670- 0.2675
1 - WH 6.7310"top" align="center">0.2650- 0.2655
5 - YEL 6.6802- 6.6929 0.2630- 0.2635
4 - YEL 6.6294- 6.6421 0.2610- 0.2615
3 - YEL 6.5786- 6.5913 0.2590- 0.2595
2 - YEL 6.5278- 6.5405 0.2570- 0.2575

1 - YEL 6.4770- 6.4897 0.2550- 0.2555

5 - ORNG 6.4262- 6.4389 0.2530- 0.2535
4 - ORNG 6.3754- 6.3881 0.2510- 0.2515
3 - ORNG 6.3246- 6.3373 0.2490- 0.2495
2 - ORNG 6.2738- 6.2865 0.2470- 0.2475
1 - ORNG 6.2223- 6.2357 0.2450- 0.2455
2 - RED 6.1722- 6.1849 0.2430- 0.2435
1 - RED 6.1214- 6.1341 0.2410- 0.2415
35. Remove the 4 diffes.

Remove the differential carrier.
37. To establish differential bearing preload, increase both the left and right differential bearing shim
thickness by 0.203 mm (0.008 in).
Spreader.
39. NOTICE: Overspreading may damage the differential housing.
NOTE: Tighten and loosen the differential carrier spreader screw to normalize the housing spreader
adapters prior to taking the final Dial Indicator reading.
Spread the differential housing to the specification.
1. Adjust the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge to zero.
2. Tighten the screw until spreading the differential housing to the specification.
40. NOTICE: To avoid galling the case, insert shims with a light coating of grease before installing
the differential assembly. If not carried out in this order, the aluminum housing may be
damaged.
Place the differential bearing shims in the differential housing.


2. Lower the differential carrier in place between the differential bearing shims.
42. NOTE: Hand-tighten the differential bearing cap bolts prior to releasing the carrier spreader.
Install the 2 differential bearing caps and the 4 differential bearing cap bolts in their original locations
and positions.
43. Loosen and remove the Differential Carrier Spreader.


47. Using the Dial Indicator Gauge with Holding Fixture, recheck the ring gear backlash.
49. Verify an acceptable pattern check. For additional information, refer to Diagnosis and Testing in this
section.
50. Install the 4 bolts and the axle housing tube.

51. Install a new stub shaft seal. For additional information, refer to Stub Shaft Pilot Bearing and Seal in
this section.
54. Remove the axle assembly from the Transmission Holding Fixture and place it on the bench.
55. NOTE: Remove all of the silicone gasket and make sure the surfaces are free of oil before applying
the new silicone gasket.
NOTE: The differential housing cover must be installed within 15 minutes of application of the
silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to
make sure the silicone sealant has correctly cured.

mounting surface as shown in the illustration.
56. Install the differential housing cover and 10 bolts.

58. Remove the fill plug and fill the axle assembly with the specified amount and type of axle lubricant.
Tighten the fill plug to 25 Nm (18 lb-ft).

Differential Bearings
Special Tool(s)
2 Jaw Puller

205-105 (T76P-4020-A3)

205-109 (T76P-4020-A9)

205-110 (T76P-4020-A10)

205-111 (T76P-4020-A11)

205-129 (T79P-4020-A18)

205-368 (T96T-4000-A)

100-002 (TOOL-4201-C)

308-021 (T75L-4201-A)

205-336 (T93P-4020-A)

205-126 (T78P-4851-A)

307-003 (T57L-500-B)



205-010 (T57L-4221-A2)

205-005 (T53T-4621-C)

205-024 (T67P-4616-A)

205-002 (TOOL-4858-E)

205-208 (T83P-4676-A)

205-460
Remover, Bearing
205-055 (T71P-4621-B)

308-047 (T77F-1102-A)

307-397
Slide Hammer
100-001 (T50T-100-A)

205-001 (TOOL-4000-E)

205-335 (T93P-4000-A) (RH)
Material
Item Specification
XG-14
XY-80W90-QL (US);
CXG-1-C (Canada)


TA-30

1 390919 Differential housing cover bolt (10 required)
3 - Differential bearing cap bolt (part of 3A412) (4
required)
4 - Differential bearing cap (part of 3A412) (2 required)
8 4A451 Differential bearing shims (2 required)
9 - Pinion gear (part of 4209)
16 4631 Drive pinion oil baffle
17 4616 Drive pinion outer bearing cup
18 4621 Drive pinion outer bearing


22 389546 Drive pinion nut and washer
Removal

Drain the fluid.
Install the Differential Housing Spreader Plate and Adapter for Differential Housing Spreader.

Spreader.

before removing them. Always install the bearing caps in their original location and position or

10. NOTE: Use wood blocks to avoid axle housing damage.

4. Remove the Differential Carrier Spreader.
16. Using the Bearing Remover and a press, remove the drive pinion inner bearing.

1. Position the Bearing Remover under the drive pinion inner bearing.
2. Using a press, remove the inner drive pinion bearing and shim.
17. NOTE: Do not damage the carrier housing while removing the pinion seal.
Pry up on the seal flange. Install gripping pliers and strike with a hammer to remove the seal.
19. Using the Bearing Cup Remover and Slide Hammer, remove the inner drive pinion bearing cup.
remove the baffle.
21. Remove the outer drive pinion bearing cup by tapping alternately on each side to prevent the drive
pinion bearing cup from becoming misaligned.

Installation
1. NOTICE: Do not omit the drive pinion bearing oil baffle or drive pinion bearing failure may
result.
If removed, position the drive pinion bearing oil baffle on the Differential Carrier Bearing Installer.
2. Using the Differential Carrier Bearing Installer, install the drive pinion bearing oil baffle.
3. Using the Drive Pinion Bearing Cup Installer, install the drive pinion bearing cups.
Assemble and position the Adapters.


1 205-109 Adapter for 205-S127 (T76P-4020-A9)
2 205-105 Adapter for 205-S127 (T76P-4020-A3)
3 4630 Drive pinion bearing (inner)
4 205-129 Adapter for 105-S127 (T79P-4020-A18)
5 205-110 Adapter for 205-S127 (T76P-4020-A10)
6 4621 Drive pinion bearing (outer)
7 205-111 Adapter for 205-S127 (T76P-4020-A11)
5. NOTE: This step duplicates final drive pinion bearing preload.
Tighten the Adapter.
6. NOTE: The Adapter must be offset to obtain an accurate reading.
Rotate the Adapter several half-turns to make sure of correct seating of the drive pinion bearings and
position the Adapter.


NOTE: A slight drag should be felt for correct drive pinion bearing adjustment shim selection. Do
not attempt to force the drive pinion bearing adjustment shim between the gauge block and the gauge
tube. This will minimize selection of a drive pinion bearing adjustment shim thicker than required,
which results in a deep tooth contact in final assembly of integral axle assemblies.
Use a drive pinion bearing adjustment shim as a gauge for drive pinion bearing adjustment shim
selection.
After the correct drive pinion bearing adjustment shim thickness has been determined,
remove all of the Adapters.
gear stem.
10. NOTE: The same drive pinion bearing from the previous steps must be used.
Install the inner drive pinion bearing.
Place the drive pinion bearing adjustment shim on the drive pinion gear.
Using a suitable press and the Drive Pinion Bearing Cone Installer, press the inner drive
pinion bearing until it is firmly seated on the pinion gear.

11. Place a new drive pinion collapsible spacer on the drive pinion gear.
12. Install the outer drive pinion bearing.
13. Install the drive pinion oil slinger.
14. NOTE: Coat the drive pinion seal lips with long-life grease.
Install the drive pinion seal on the Drive Pinion Oil Seal Installer.
drive pinion seal.
16. Lightly lubricate the drive pinion gear splines with rear axle lubricant.

17. Position the drive pinion gear in the axle housing.
18. Position the pinion flange.
20. Apply a small amount of axle lubricant to the washer side of the new pinion nut and install the new
pinion nut.
21. NOTICE: Do not loosen the pinion nut to reduce drive pinion bearing preload under any
circumstance. If it is necessary to reduce drive pinion bearing preload, install a new drive
Install the Drive Pinion Flange Holding Fixture and tighten the pinion nut. Refer to the torque
specifications in the Specifications portion of this section.
Rotate the drive pinion gear occasionally to make sure the drive pinion bearings are seating
22. Press the left and right differential bearing on the differential case.
1. Position the differential bearing.
2. Using the Differential Side Bearing Installer, press the differential bearing on the differential
case.




1. Attach the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.
2. Position the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge tip
centrally on a drive tooth.
4. Turn the differential ring gear without turning the drive pinion gear. Record the indicator
reading. The allowable backlash is 0.203 mm (0.008 in) to 0.305 mm (0.012 in) and must not
vary more than 0.101 mm (0.004 in) between points measured.
Backlash Thickness
Change Change
Required Required
mm Inch mm Inch
0.025 0.001 0.050 0.002
0.050 0.002 0.050 0.002
0.076 0.003 0.101 0.004

0.101 0.004 0.152 0.006

0.127 0.005 0.152 0.006
0.152 0.006 0.203 0.008
0.177 0.007 0.254 0.010
0.203 0.008 0.254 0.010
0.228 0.009 0.304 0.012
0.254 0.010 0.355 0.014
0.279 0.011 0.355 0.014
0.304 0.012 0.406 0.016
0.330 0.013 0.457 0.018
0.335 0.014 0.457 0.018
0.381 0.015 0.508 0.020
Differential Shim Size Chart - 4067
Numbers of Stripes and Color Code Dimension A

mm Inch
2 - C-COAL 7.7978- 7.8105 0.3070- 0.3075
1 - C-COAL 7.7470- 7.7597 0.3050- 0.3055
5 - BLU 7.6962- 7.7089 0.3030- 0.3035
4 - BLU 7.6454- 7.6581 0.3010- 0.3015
3 - BLU 7.5946- 7.6073 0.2990- 0.2995
2 - BLU 7.5458- 7.5565 0.2970- 0.2975
1 - BLU 7.493- 7.505 0.2950- 0.2955
5 - PINK 7.4422- 7.4549 0.2930- 0.2935
4 - PINK 7.3914- 7.4041 0.2910- 0.2915
3 - PINK 7.3406- 7.3533 0.2890- 0.2895
2 - PINK 7.2898- 7.3025 0.2870- 0.2875
1 - PINK 7.2390- 7.2517 0.2850- 0.2855
5 - GRN 7.1882- 7.2009 0.2830- 0.2835
4 - GRN 7.1374- 7.1501 0.2810- 0.2815
3 - GRN 7.0866- 7.0993 0.2790- 0.2795
2 - GRN 7.0358- 7.0485 0.2770- 0.2775
1 - GRN 6.9850- 7.0485 0.2750- 0.2755
5 - WH 6.9342- 6.9469 0.2730- 0.2735
4 - WH 6.8834- 6.8961 0.2710- 0.2715
3 - WH 6.8326- 6.8453 0.2690- 0.2695
2 - WH 6.7818- 6.7945 0.2670- 0.2675
1 - WH 6.7310- 6.7437 0.2650- 0.2655
5 - YEL 6.6802- 6.6929 0.2630- 0.2635
4 - YEL 6.6294- 6.6421 0.2610- 0.2615
6.5786- 6.5913 0.2590- 0.2595

2 - YEL 6.5278- 6.5405 0.2570- 0.2575

1 - YEL 6.4770- 6.4897 0.2550- 0.2555
5 - ORNG 6.4262- 6.4389 0.2530- 0.2535
4 - ORNG 6.3754- 6.3881 0.2510- 0.2515
3 - ORNG 6.3246- 6.3373 0.2490- 0.2495
2 - ORNG 6.2738- 6.2865 0.2470- 0.2475
1 - ORNG 6.2223- 6.2357 0.2450- 0.2455
2 - RED 6.1722- 6.1849 0.2430- 0.2435
1 - RED 6.1214- 6.1341 0.2410- 0.2415
33. Remove the 4 differential bearing cap bolts.

36. Install the Dial Indiclding Fixture, Clutch Housing Gauge and Differential Carrier Spreader.
NOTE: Tighten and loosen the differential carrier spreader screw to normalize the housing spreader

2. Tighten the screw until spreading the differential housing to the specification.
38. NOTICE: To avoid galling the case, insert shims with a light coating of grease before installing
the differential assembly. If not carried out in this order, the aluminum housing can be
damaged.


40. NOTE: Hand-tighten the differential bearing cap bolts prior to releasing the Differential Carrier
Spreader.
Install the 2 differential bearing caps and the 4 differential bearing cap bolts in their original locations
and positions.


45. Using the Dial Indicator Gauge with Holding Fixture, recheck the ring gear backlash.
section.
48. Install the axle housing tube and the 4 bolts.

this section.

54. Install the differential housing cover and the 10 bolts.

56. Remove the fill plug and fill the axle assembly with the specified type and amount of axle lubricant.

Differential Carrier
Special Tool(s)

205-368 (T96T-4000-A)

100-002 (TOOL-4201-C)

308-021 (T75L-4201-A)

307-003 (T57L-500-B)

307-397
Slide Hammer
100-001 (T50T-100-A)

205-001 (TOOL-4000-E)

205-335 (T93P-4000-A) (RH)
Material
Item Specification
XY-80W90-QL (US);
CXG-1-C (Canada)
Differential Carrier 2105

ItemPart Number Description

3 - Differential bearing cap bolt (part of 3A412) (4
required)
4 - Differential bearing cap (part of 3A412) (2 required)
Removal

Drain the fluid.

7. Position the Differential Carrier Spreader on the spreader adapters.
8. Install the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.

9. NOTICE: Overspreading may damage the component.

3. Remove the Dial Indicator Gauge with Holding Fixture.
before removing them. Always install the differential bearing caps in their original positions or

11. NOTE: Use wood blocks to avoid axle housing damage.
NOTE: Index-mark the position of the differential bearing shims. The differential bearing shims must
be installed in their original locations and positions.
Remove the differential carrier from the axle housing.

3. Remove the differential carrier.
Installation
1. NOTE: Make sure the Dial Indicator needle is in the spreader adapter hole.

Install the Dial Indicator Gauge with Holding Fixture, Clutch Housing Gauge and Differential Carrier
Spreader.
2. NOTICE: Overspreading may damage the component.
Remove the Dial Indicator.
3. NOTICE: Never attempt to drive the differential bearing shim in place. Permanent damage to
the machined axle housing surfaces may occur.
Position the differential bearing shims.
1. Apply a light coating of grease to one side of the differential bearing shims to help hold them
in place.
2. Position the differential bearing shims.
4. NOTE: Push the differential carrier downward to fully seat the differential bearing cups in the axle
housing.
Position the differential carrier.

2. Lower the differential assembly in place between the differential bearing shims.

5. Install the differential bearing caps in their original positions and tighten with the housing still spread.
1. Position the 2 differential bearing caps.
1. Attach the Dial Indicator Gauge with Holding Fixture.
2. Position the Clutch Housing Gauge tip centrally on a drive tooth.
4. Turn the differential ring gear without turning the drive pinion gear.
8. Install the axle housing tube and the 4 bolts.


this section.
14. Install the differential housing cover and the 10 differential housing cover bolts.

16. Remove the fill plug and fill the axle assembly with the specified type and amount of axle lubricant.

Axle
Special Tool(s)
2 Jaw Puller

205-105 (T76P-4020-A3)

205-109 (T76P-4020-A9)

205-110 (T76P-4020-A10)

205-111 (T76P-4020-A11)

205-129 (T79P-4020-A18)

205-368 (T96T-4000-A)

100-002 (TOOL-4201-C)

308-021 (T75L-4201-A)

205-336 (T93P-4020-A)

205-126 (T78P-4851-A)

307-003 (T57L-500-B)
Installer, Differential Carrier Bearings

Axle 2113

205-010 (T57L-4221-A2)

205-005 (T53T-4621-C)

205-024 (T67P-4616-A)

205-002 (TOOL-4858-E)

205-208 (T83P-4676-A)

205-460
Remover, Bearing
205-055 (T71P-4621-B)

308-047 (T77F-1102-A)

307-397
Slide Hammer
100-001 (T50T-100-A)

205-001 (TOOL-4000-E) or equivalent

205-335 (T93P-4000-A) (RH)
Step Plate
205-D061 (D83T-4205-C2)
Material
Item Specification
XG-14
XY-80W90-QL (US);
Axle 2114

CXG-1-C (Canada)
TA-30
Front Axle Assembly - Disassembled View

1 3C202 Differential carrier assembly
2 4338 Axle housing vent
3 4B422 Circlips
6 3A380 Intermediate shaft
7 3B210 Axle housing tube
8 4B413 Axle shaft bearing assembly (outer)
9 4B416 Axle shaft dust seal
10 5638 Front axle support mounting bushings (3 required)
11 N808703 Axle housing tube bolt (4 required)
12 4121 Axle identification tag
13 373098 Fill plug
14 4369 O-ring
Disassembly

Drain the fluid.
Remove the bolts.
Remove the differential housing cover.
Front Axle Assembly - Disassembled View 2115

7. Position the Differential Carrier Spreader on the spreader adapters.

8. Install the Dial Indicator Gauge with Holding Fixture and Clutch Holding Gauge.

3. Remove the Dial Indicator Gauge with Holding Fixture.
10. NOTE: Mark the differential bearing caps Top or Bottom and LH or RH appropriately before
removing them. Always install the bearing caps in their original place and position.

2. Remove the differential bearing caps.
11. NOTICE: Use wood blocks to avoid axle housing damage.

12. Index-mark the axle U-joint flange to the pinion stem.
17. Discard the drive pinion collapsible spacer.

18. NOTICE: Do not damage the carrier housing while removing the pinion seal.
Pry up on the seal flange. Install gripping pliers, and strike with a hammer to remove the seal.
20. Using the Bearing Cup Remover and Slide Hammer, remove the inner pinion bearing cup.
remove the baffle.
22. Remove the outer pinion bearing cup by tapping alternately on each side to prevent the cup from
cocking.

23. Using the Bearing Remover and a suitable press, remove the pinion bearing.
24. NOTE: A drive pinion bearing adjustment shim sits under the pinion bearing. Use a micrometer to
measure the shim thickness. Record the measurement for comparison to the shim gauge reading taken
prior to installing the pinion bearing.
Remove and measure the drive pinion bearing adjustment shim.
Remove and discard the 10 bolts and remove the ring gear.
26. Using the 2 Jaw Puller and Step Plate, remove the differential bearings.
Assembly
1. NOTICE: Do not omit the pinion bearing oil baffle; bearing failure may result.
If removed, position the baffle on the Drive Carrier Bearings Installer.

2. Using the Drive Carrier Bearings Installer, install the baffle.
3. NOTE: Always install new pinion bearings when installing new pinion bearing cups.
Lightly oil the new pinion bearing cups and pinion bearings with front axle lubricant.
4. Using the Drive Pinion Bearing Cup Installer, install the bearing cups.
5. NOTE: The pinion bearings assembled in this procedure step must be used at final assembly.
Assemble and position the Adapters and the pinion bearings in the carrier housing.
1. Position the screw adapter.

2. Position the aligning adapter.
3. Position the pinion bearing.
4. Position the gauge disc adapter.
5. Position the gauge block adapter.
6. Position the pinion bearing.
7. Thread on the handle adapter.

6. NOTE: This step duplicates final pinion bearing preload.
Tighten the Adapter to simulate bearing preload.
7. NOTE: Offset the gauge block adapter to obtain an accurate reading.
Rotate the gauge block Adapter several half-turns to make sure the pinion bearings seat correctly and
position the gauge block adapter.


9. NOTE: Use only flat, clean drive pinion bearing adjustment shims.
NOTE: Do not attempt to force the shim between the gauge block adapter and the gauge tube adapter.
A slight drag indicates correct shim selection.
Check the adjustment shim thickness between the gauge block adapter and the gauge tube
adapter.
After determining the correct shim thickness, remove the Drive Pinion Gauge Tube.
10. NOTE: The same pinion bearings from the previous steps must be used.
Install the pinion bearing.
Place the drive pinion bearing adjustment shim on the pinion gear.
Using a suitable press and the Drive Pinion Bearing Cone Installer, press the pinion bearing
until it is firmly seated on the pinion gear.
11. Place a new drive pinion collapsible spacer on the pinion stem.
12. Install the outer pinion bearing.
13. Install the slinger.

14. NOTE: Coat the lips of the pinion seal with front axle lubricant.
Place the pinion seal on the Drive Pinion Oil Seal Installer.
15. Place the Drive Pinion Oil Seal Installer and seal in the pinion seal bore and drive the seal into place.
16. Lightly lubricate the pinion gear splines with front axle lubricant.
17. Position the drive pinion in the housing.
18. NOTICE: Never install the drive pinion U-joint flange with a hammer or power tools.
NOTE: Disregard the scribe marks if installing a new flange.
Align the index marks and position the U-joint flange on the drive pinion.
19. Using the Drive Pinion Flange Installer, install the drive pinion U-joint flange.
20. Apply a small amount of lubricant to the washer side of the new pinion nut, and install the nut.
21. NOTICE: Do not loosen the pinion nut to reduce preload under any circumstance. If it is
necessary to reduce preload, install a new drive pinion collapsible spacer and pinion nut or

Install the Drive Pinion Flange Holding Fixture and tighten the pinion nut. Refer to the torque
specifications in the Specifications portion of this section.
Rotate the pinion gear occasionally to make sure the pinion bearings are seating correctly.
Take frequent pinion bearing torque preload readings by rotating the pinion gear with a Nm
(lb-in) torque wrench.
22. Use a fine flat file to remove any burrs or nicks from the ring gear mounting surface.

2. Hand-start 3 ring gear bolts to align the holes in the differential ring gear and the differential
assembly.
differential gear teeth facing downward.
24. Install the remaining new bolts.


25. NOTE: Press against the bearing inner core only.
Using a suitable press and the Differential Side Bearing Installer, install the differential bearings.
1. Position the appropriate differential bearing (RH or LH).

2. Using a suitable press and the Differential Side Bearing Installer, install the differential
bearing.
Repeat the procedure for the other differential bearing.

28. NOTE: Apply pressure to the left side to make sure the left bearing cup is seated.

29. Install progressively thicker differential bearing shims on the right side until the thickest differential

34. Using the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge, measure the ring
gear backlash at 4 places to obtain a consistent reading.
35. NOTE: If the backlash is not within the specifications, correct it by increasing the thickness of one
differential bearing shim and decreasing the thickness on the other differential bearing shim by the
same amount.
To increase the backlash, install a thicker differential bearing shim and a thinner differential bearing
shim as shown.

36. To decrease the backlash, install a thicker differential bearing shim and a thinner differential bearing
shim as shown.
37. Select the appropriate shim by the thickness or the stripe color.
Backlash Thickness
Change Change
Required Required
mm Inch mm Inch
0.025 0.001 0.050 0.002
0.050 0.002 0.050 0.002
0.076 0.003 0.101 0.004
0.101 0.004 0.152 0.006
0.127 0.005 0.152 0.006
0.152 0.006 0.203 0.008
0.177 0.007 0.254 0.010
0.203 0.008 0.254 0.010
0.228 0.009 0.304 0.012
0.254 0.010 0.355 0.014
0.279 0.011 0.355 0.014
0.304 0.012 0.406 0.016
0.330 0.013 0.457 0.018
0.335 0.014 0.457 0.018
0.381 0.015 0.508 0.020

Differential Shim Size Chart
Stripes/Color mm Inch
2 - C-COAL 7.7978-7.8105 0.3070-0.3075
1 - C-COAL 7.7470-7.7597 0.3050-0.3055
5 - BLU 7.6962-7.7089 0.3030-0.3035
4 - BLU 7.6454-7.6581 0.3010-0.3015
3 - BLU 7.5946-7.6073 0.2990-0.2995
2 - BLU 7.5458-7.5565 0.2970-0.2975
1 - BLU 7.4930-7.57.3406-7.3533 0.2950-0.2955
5 - PINK 7.2898-7.3025 0.2930-0.2935
4 - PINK 7.2390-7.2517 0.2910-0.2915
3 - PINK 7.1882-7.2009 0.2890-0.2895
2 - PINK 7.1374-7.1501 0.2870-0.2875
1 - PINK 7.0866-7.0993 0.2850-0.2855
5 - GRN 7.0358-7.0485 0.2830-0.2835
4 - GRN 6.9850-6.9977 0.2810-0.2815
3 - GRN 6.9342-6.9469 0.2790-0.2795
2 - GRN 6.8834-6.8961 0.2770-0.2775
1 - GRN 6.8326-6.8453 0.2750-0.2755
5 - WH 6.7818-6.7945 0.2730-0.2735
4 - WH 6.7310-6.7437 0.2710-0.2715
3 - WH 6.6802-6.6929 0.2690-0.2695
2 - WH 6.6294-6.6421 0.2670-0.2675
1 - WH 6.5786-6.5913 0.2650-0.2655
5 - YEL 6.5278-6.5405 0.2630-0.2635
4 - YEL 6.4770-6.4897 0.2610-0.2615

3 - YEL 6.4262-6.4389 0.2590-0.2595
2 - YEL 6.3754-6.3881 0.2570-0.2575
1 - YEL 6.3246-6.3373 0.2550-0.2555
5 - ORNG 6.2738-6.2865 0.2530-0.2535
4 - ORNG 6.2223-6.2357 0.2510-0.2515
3 - ORNG 6.1722-6.1849 0.2490-0.2495
2 - ORNG 6.1214-6.1341 0.2470-0.2475
1 - ORNG 0.2450-0.2455
2 - RED 0.2430-0.2335
1 - RED 0.2410-0.2415

Spreader.
NOTE: Tighten and loosen the differential carrier spreader adapters to normalize the housing

2. Tighten the screw until spreading the differential housing to the specifications.

43. NOTICE: To avoid galling the case, insert the shims with a light coating of grease before
installing the differential carrier.

45. NOTE: Hand-tighten the differential bearing cap bolts prior to releasing the Differential Carrier
Spreader.
Install the 2 differential bearing caps and 4 bolts in their original location.

48. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, recheck the ring
gear backlash.
section.
51. Assemble the axle housing tube.

Align the bolt holes and position the axle tube.
Position the axle identification tag.
Install the 4 bolts.
this section.
54. Insert the intermediate shaft and engage the circlip with the side gears.
55. Remove the axle assembly from the Holding Fixture and place it on the bench.

57. Install the differential housing cover and the 10 cover bolts.
59. Remove the fill plug and fill the axle assembly with the specified type and amount of lubricant.


Differential Case
Material
Item Specification
XY-80W90-QL (US);
TA-25

1 4236 Differential side gears
2 4228 Differential side gear thrust washers
3 4215 Differential pinion gears
4 4230 Differential pinion thrust washers
5 4209 Differential ring gear
6 4241 Differential pinion shaft lock bolt
7 4211 Differential pinion shaft
8 4204 Differential case
9 4216 Differential ring gear bolt (10 required)
Diassembly
1. Remove the differential carrier. For additional information, refer to Differential Carrier in this section.
Remove and discard the 10 bolts. Remove the differential ring gear.
Differential Case 2135

3. Remove the differential pinion shaft bolt.
4. Remove the differential pinion shaft.
5. Remove the differential pinion thrust washers and the differential pinion gears.
1. Rotate the differential pinion gears to the differential case window, and remove them.
2. Separate the thrust washers from the gears.
6. Remove the differential side gears and the differential side gear thrust washers.
Assembly
1. Lubricate the differential side gear thrust washers and the differential side gear journals with axle
lubricant.
2. Position the differential side gear thrust washers on the differential side gears.

3. Position the differential side gears.
4. Lubricate the differential pinion thrust washers and the differential pinion gears with axle lubricant
and assemble them.
5. Engage the differential pinion gears opposite the differential side gears.
6. Rotate the differential pinion gears to align with the differential pinion shaft bore.
7. Insert the differential pinion shaft.

8. NOTE: If a new pinion shaft bolt is unavailable, coat the threads with sealer.
Install a new differential pinion shaft bolt.

2. Hand-start 3 ring gear bolts to align the holes in the differential ring gear and the differential
assembly.
10. Install the 7 remaining new bolts.

Tighten all 10 bolts to 128 Nm (95 lb-ft).
11. Install the differential carrier. For additional information, refer to Differential Carrier in this section.


SECTION 205-04: Front Drive Halfshafts 2011 Expedition, Navigator Workshop Manual
Material

Capacity
Constant Velocity Joint Grease WSS-M1C258-A1 -
(High Temperature)
XG-5
Item Specification
Left halfshaft assembled length 406.45 mm (16.00 in)
Right halfshaft assembled length 411.85 mm (16.21 in)

Brake flexible hose bracket bolt 30 22 -
Wheel hub nut 27 20 -

Front Drive Halfshafts
The front drive halfshafts consist of the following:
Inner CV joints
Outer CV joints
Interconnecting shafts
Convoluted CV joint boots
CV joint boot clamps
Special CV high-temperature grease
Tripod joint housings
Ball and cage housings
A circlip stopper that holds the cross-groove inboard race assembly (inboard CV joint) together
A circlip that retains the splined inboard CV joint to the differential side gear
The front drive halfshafts link the front axle to the front wheel hubs. The CV joints allow the halfshafts to
rotate smoothly through the required changes in angles between the stationary axle and the varying angles of
the front wheels including jounce and rebound plus changes while turning. The CV joints are either tri-lobed
style or the caged ball type depending on inboard or outboard. New halfshaft components are available as kits
containing grease, boots and clamps.
Halfshaft Handling
Handle all halfshaft components carefully during removal and installation and during various component
disassembly and assembly procedures.
Never pick up or hold the halfshaft only by the inboard or outboard CV joint.
Do not overangle the CV joints.
Damage will occur to an assembled inboard CV joint if it is overplunged outward from the joint
housing.
Never use a hammer to remove or install the halfshafts from the hub.
Never use the halfshaft assembly as a lever to position other components. Always support the free end
of the halfshaft.
Do not allow the boots to contact sharp edges or hot exhaust components.
Handle the halfshaft only by the interconnecting shaft to avoid pull-apart and potential damage to the
CV joints.
Excessive pulling force on the interconnecting shaft between joints of the halfshaft will result in
internal joint damage. Axial loads used in assisting removal must be applied through the inboard joint
housing only.
Do not drop assembled halfshafts. The impact will cut the boots from the inside without evidence of
external damage.
Do not remove the outer CV joint by pulling on the interconnecting shaft.
Inspect all machined surfaces and splines for damage.
Front Drive Halfshafts 2141


Front Drive Halfshafts

Halfshaft
Special Tool(s)
Halfshaft Remover
205-832
Slide Hammer
100-001 T50T-100-A

1 1131 Dust cap
2 N802827 Wheel hub nut
3 W520215 Tie-rod nut
5 W505211 Integrated Wheel End (IWE) bolts (3 required)
6 - Vacuum vent and apply tube
7 - Wheel speed sensor harness bracket bolt
8 - Wheel speed sensor harness bracket (part of 2C204)
9 - Brake flexible hose retainer (part of 2078)
10 W611633 Brake flexible hose bracket bolt
NOTICE: Whenever a halfshaft is removed, a new circlip and stub shaft pilot bearing seal must be
installed or damage to the component may occur.
Halfshaft 2144
100-02 .
2. Remove the dust cap.
3. Remove and discard the wheel hub nut.

5. Detach the flexible hose retainer from the speed sensor harness.
6. Remove the brake flexible hose bracket bolt and disconnect the bracket from the wheel knuckle.
7. Remove the vacuum/vent tube at the vacuum/vent port of the Integrated Wheel End (IWE)
disconnect.
8. Remove the 3 IWE bolts.


Disconnect the tie-rod end from the wheel knuckle.

Disconnect the upper ball joint from the wheel knuckle.
11. NOTE: Do not damage the hub seal.
NOTE: Allow the steering knuckle to swing outboard while keeping the CV shaft pushed inboard.
Once clearance is available, remove the CV shaft joint outboard end and IWE disconnect from the
steering knuckle hub bearing.
12. Remove the IWE disconnect from the outboard CV joint housing.
Halfshaft 2145
13. Using the Halfshaft Remover and Slide Hammer, remove the halfshaft from the differential and the
intermediate shaft.
14. Remove and discard the circlip and the stub shaft seal. For additional information, refer to Section
205-03 .
15. NOTICE: Verify the spline engagement by checking for spline lash before installing the
halfshaft nut or component damage may occur.
Halfshaft 2146
Halfshaft
Material
Item Specification
Constant Velocity Joint Grease WSS-M1C258-A1
(High Temperature)
XG-5

1 3B436B Outboard CV joint and interconnecting shaft assembly
2 3A331A Outboard CV boot
3 3A331B Inboard CV boot
4 4B422 Snap ring
5 3B414 Inboard CV joint housing
6 - Inner race (part of 3B436 RH/ 3B437 LH)
7 - Ball (8 required) (part of 3B436 RH/ 3B437 LH)
8 - Ball cage (part of 3B436 RH/ 3B437 LH)
9 3B426 Retaining ring (part of 3B436 RH/ 3B437 LH)
Disassembly
1. Remove the halfshaft from the vehicle. For additional information, refer to Halfshaft in the Removal
and Installation portion of this section.
2. Remove the 2 boot clamps.
Halfshaft 2147
3. Separate the boot from the inboard CV joint housing.
4. Remove the retaining ring.
5. Remove the inboard CV joint housing.
6. Index-mark the inner race and ball cage.
7. Remove the 6 balls.
8. Remove the snap ring.
Halfshaft 2148
9. Remove the inner race and the ball cage.
10. Remove the inboard boot.
12. Remove the outboard boot.
13. NOTE: If the grease is contaminated, clean and inspect the joint for wear. Install a new outboard CV
joint and interconnecting shaft assembly if worn/damaged.
Check the CV joint grease for contamination.
Assembly
1. Position the outboard boot on the shaft.
Halfshaft 2149
2. Pack the outboard CV joint with 165 g (5.82 oz) of grease.

1. Use CV joint grease or equivalent provided in the boot kit.
2. Spread any remaining grease from the kit evenly inside the boot.
3. Install the outboard boot.

1. Clean the boot mounting surface.
2. Seat the boot in the joint boot groove.
4. Using a suitable boot clamp installer (such as Snap-On stock #YA3050 or equivalent) install the
large boot clamp.
small boot clamp.
6. Position the boot clamp on the shaft.
Halfshaft 2150
7. Position the inboard boot on the shaft.
8. Position the ball cage on the shaft with the tapered end facing the boot.
9. NOTE: Align the index marks.
Position the inner race on the shaft with the counterbored end facing the boot.
10. Install the snap ring.
11. Lubricate and position the 6 balls.

Use CV joint grease or equivalent provided in the boot kit.
Halfshaft 2151
12. Fill the inboard CV joint housing with 235 g (8.29 oz) of grease.
13. Position the boot clamp on the inboard CV joint housing.
14. Position the inboard CV joint housing on the ball and race assembly.
15. Install the retaining ring.
16. Remove any excess grease from the mating surface. Seat the boot in the joint boot groove.
Halfshaft 2152
17. Set the halfshaft assembled length to specification. For additional information, refer to Specifications
in this section.
18. NOTICE: Use care when inserting the screwdriver or damage to the boot may occur.
Insert a dull screwdriver blade under the boot to release the pressure.
large boot clamp.
small boot clamp.
21. NOTE: Maintain a clean work surface.
Compress the Integrated Wheel End (IWE) disconnect on the bench to collapse the vacuum chamber.
Halfshaft 2153
22. While the IWE disconnect is collapsed, install a vacuum cap on the vacuum port.
23. NOTICE: Do not install the Integrated Wheel End (IWE) end disconnect in the knuckle. It must
be installed on the outer Constant Velocity (CV) joint housing or damage to the component may
occur.
Install the IWE disconnect on the outer CV joint housing.
halfshaft nut or damage to the component may occur.
Install the halfshaft in the vehicle. For additional information, refer to Halfshaft in the Removal and
Installation portion of this section.
Halfshaft 2154
Halfshaft 2155
SECTION 205-05: Rear Drive Halfshafts 2011 Expedition, Navigator Workshop Manual
Material

Capacity
Constant Velocity Joint Grease WSS-M1C258-A1 -
(High Temperature)
XG-5
Item Specification
Halfshaft assembled length, LH 946 mm (37.24 in)
Halfshaft assembled length, RH 905 mm (35.63 in)
Lower trailing arm-to-wheel knuckle bolt 103 76
Stabilizer bar link nut 63 46
Toe link-to-wheel knuckle bolt 225 166
Upper arm-to-wheel knuckle nut 103 76
Upper trailing arm-to-wheel knuckle bolt 250 184
Wheel hub nut 250 184
Halfshaft 2156
Halfshaft 2157
Rear Drive Halfshafts
NOTE: The outboard CV joint shaft assembly should not be disassembled.
NOTE: Due to the sub-assembly process, if the outboard CV boot needs replacement, the inboard CV boot
must also be replaced. However, the inboard CV boot can be replaced by itself.
The rear drive halfshafts consist of the following:
Inner CV joints
Outer CV joints
Interconnecting shafts
Convoluted CV joint boots
CV joint boot clamps
Special CV high-temperature grease
CV joint housings
Ball and cage housings
A circlip stopper that holds the cross-groove inboard race assembly (inboard CV joint) together
A circlip that retains the splined inboard CV joint to the differential side gear
The RH and LH halfshafts are different lengths, with the LH halfshaft being the longer of the 2.
The rear drive halfshafts link the rear axle to the rear wheel hubs. The CV joints allow the halfshafts to rotate
smoothly through the required changes in angles between the stationary axle and the varying angles of the
front wheels including jounce and rebound plus changes while turning. The CV joints are caged ball type.
New halfshaft components are available as kits containing grease, boots and clamps.
Halfshaft Handling
Handle all halfshaft components carefully during removal and installation and during various component
disassembly and assembly procedures.
Never pick up or hold the halfshaft only by the inboard or outboard CV joint.
Do not overangle the CV joints.
Damage will occur to an assembled inboard CV joint if it is overplunged outward from the joint
housing.
Never use a hammer to remove or install the halfshafts from the hub.
Never use the halfshaft assembly as a lever to position other components. Always support the free end
of the halfshaft.
Do not allow the boots to contact sharp edges or hot exhaust components.
Handle the halfshaft only by the interconnecting shaft to avoid pull-apart and potential damage to the
CV joints.
Excessive pulling force on the interconnecting shaft between joints of the halfshaft will result in
internal joint damage. Axial loads used in assisting removal must be applied through the inboard joint
housing only.
Do not drop assembled halfshafts. The impact will cut the boots from the inside without evidence of
external damage.
Do not remove the outer CV joint by pulling on the interconnecting shaft.
Inspect all machined surfaces and splines for damage.
Rear Drive Halfshafts 2158


Rear Drive Halfshafts

Halfshaft
Special Tool(s)
Adapter for 303-224 (Handle)

205-153 (T80T-4000-W)
Remover, Halfshaft
205-529

204-592

3 W520213 Stabilizer bar link nut
5 W71170 Lower trailing arm-to-wheel knuckle bolts (2
required)
6 W707772 Wheel hub nut
7 5A970 LH/ 5A971 Wheel knuckle
RH
8 4B402 Rear halfshaft
9 7G273 Washer
NOTE: This procedure applies to both rear halfshaft assemblies.
NOTE: Always install a new differential stub shaft seal whenever a rear halfshaft is removed. For additional
Halfshaft 2161
1. NOTICE: Do not loosen the rear axle wheel hub retainer until after the wheel and tire assembly
is removed from the vehicle. Wheel bearing damage will occur if the wheel bearing is unloaded
with the weight of the vehicle applied.
NOTICE: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense. New parts must
be installed with the same part numbers or equivalent part, if replacement is necessary. Do not
use a replacement part of lesser quality or substitute design. Torque values must be used as
specified during reassembly to make sure of correct retention of these parts.
With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .
Remove and discard the wheel hub nut and the washer.
4. Separate the halfshaft from the knuckle.
5. Remove the brake disc. For additional information, refer to Section 206-04 .


9. Remove and discard the stabilizer bar link nut.

10. Remove and discard the toe link-to-wheel knuckle bolt.

11. Disconnect the anti-lock brake sensor at the connector and open the wire retaining clips.
Halfshaft 2162
12. Compress the spring, depress the retaining tabs and detach the parking brake cable from the wheel
knuckle.
13. Remove and discard the 2 lower trailing arm-to-wheel knuckle bolts.
14. Rotate the top of the knuckle assembly outboard and remove the halfshaft from the knuckle.
15. Using the Halfshaft Remover and Adapter (Handle), disengage the inboard CV joint housing from the
differential side gear.
16. Remove the halfshaft assembly from the vehicle.
17. Remove and discard the halfshaft retainer circlip.
18. NOTE: Install a new differential stub shaft seal. For additional information, refer to Section 205-02 .
NOTE: Always install the halfshaft with a new retainer circlip and a new wheel hub nut.
Halfshaft 2163
Halfshaft 2164
Halfshaft Joint
Special Tool(s)
Installer, Constant Velocity Joint Boot

Clamp
205-343 (T95P-3514-A)
Material
Item Specification
Constant Velocity Joint Grease WSS-M1C258-A1
(High Temperature)
XG-5
Disassembly
1. Remove the halfshaft from the vehicle. For additional information, refer to Halfshaft in the Removal
and Installation portion of this section.
2. NOTE: Do not damage the boot.
Remove the 2 boot clamps.
3. Separate the boot from the inboard CV joint housing.
4. Remove the retaining ring.
Halfshaft Joint 2165

5. Remove the inboard CV joint housing.
6. Index-mark the inner race and ball cage.
7. Remove the 8 balls.
9. Remove the inner race and the ball cage.
10. Remove the inboard boot.

12. Remove the outboard boot.
13. NOTE: If the grease is contaminated, clean and inspect the joint for wear. Install a new outboard CV
joint and interconnecting shaft assembly if worn/damaged.
Check the grease for contamination.
Assembly
1. Position the outboard boot on the shaft.
2. Pack the outboard CV joint with 175 g (6.17 oz) of grease.

1. Use CV joint grease or equivalent provided in the boot kit.
2. Spread any remaining grease from the kit evenly inside the boot.

3. Install the outboard boot.
1. Clean the boot mounting surface.
2. Seat the boot in the joint boot groove.
4. Position the 2 boot clamps.
5. NOTE: Tighten the through-bolt until the tool is in the closed position.
Using the Constant Velocity Joint Boot Clamp Installer, install the 2 boot clamps.
6. Position the boot clamp on the shaft.
7. Position the inboard boot on the shaft.
8. Position the ball cage on the shaft with the tapered end facing the boot.

9. NOTE: Align the index marks.
Position the inner race on the shaft with the counterbored end facing the boot.
11. Lubricate and position the 8 balls.

12. Fill the inboard CV joint housing with 225 g (7.94 oz) of grease.
13. Position the boot clamp on the inboard CV joint housing.

14. Position the inboard CV joint housing on the ball and race assembly.
15. Install the retaining ring.
16. Remove any excess grease from the mating surface. Seat the boot in the joint boot groove.
17. Set the halfshaft assembled length to specification. For additional information, refer to Specifications
in this section.
18. NOTE: Do not damage the boot.
Insert a dull screwdriver blade under the boot to release the pressure.

19. NOTE: Tighten the through-bolt until the tool is in the closed position.
Using the Constant Velocity Joint Boot Clamp Installer, install the 2 boot clamps.
halfshaft nut or damage to the component may occur.
Install the halfshaft in the vehicle. For additional information, refer to Halfshaft in the Removal and
Installation portion of this section.

SECTION 206-00: Brake System - General Information 2011 Expedition, Navigator Workshop Manual
Material

Capacity
High Performance DOT 3 WSS-M6C62-A or 1,420 ml
Motor Vehicle Brake Fluid WSS-M6C65-A1 (3 pt)
PM-1-C (US); CPM-1-C
(Canada)
Metal Brake Parts Cleaner - -
PM-4-A or PM-4-B (US);
CPM-4 (Canada)
Silicone Brake Caliper ESE-M1C171-A -
Grease and Dielectric
Compound
XG-3-A
Item Specification
Brake Disc
Front brake disc minimum thickness 32.0 mm (1.259 in)
Rear brake disc minimum thickness 20.0 mm (0.787 in)
Brake Pads
Brake pad maximum taper wear (in any direction) 3.0 mm (0.118 in)
Brake pad minimum thickness 2.0 mm (0.079 in)
Caliper bleeder screws 15 133
Master cylinder brake tube fittings 20 177



SECTION 206-00: Brake System - General Information
Manual
Brake System
The brake system consists of the following components:
Front and rear disc brakes

Cable/drum-in-hat actuated parking brake
Brake master cylinder and fluid reservoir
Vacuum-assisted power brake booster
Four-wheel ABS
Red brake warning indicator
The brake pedal is connected to the power brake booster, which is connected to the brake master cylinder.
When the brake pedal is pressed, brake fluid is pushed through the double-walled steel tubes and flexible
hoses to the front and rear disc brake calipers. The brake fluid enters the disc brake calipers, forcing the
caliper pistons and brake pads outward against the brake disc friction surface, slowing or stopping rotation.
When the brake pedal is released, brake fluid pressure is relieved, returning the front and rear disc brake
caliper pistons and brake pads to the unapplied position.
For information on the following:
Front disc brakes, refer to Section 206-03 .

Rear disc brakes, refer to Section 206-04 .
Parking brake actuation, refer to Section 206-05 .
Hydraulic brake actuation, refer to Section 206-06 .
Vacuum-assisted power brake booster, refer to Section 206-07 .
ABS, refer to Section 206-09 .
Brake System 2174


Manual
Brake System
Applying the brake pedal uses lever action to push a rod into the brake booster, which through the use of
vacuum, boosts the force of the rod and then transmits this force to the primary piston in the master cylinder.
This produces hydraulic pressure in the master cylinder. Ts pressure builds in the master cylinder and brake
tubes as the brake pedal is applied further. The pressure between the primary and secondary piston forces the
secondary piston to compress, building pressure in its circuit. The hydraulic pressure is transmitted by brake
fluid through the brake tubes to the ABS Hydraulic Control Unit (HCU), which then distributes that pressure
to the individual brake calipers. The brake calipers use hydraulic pressure to apply the pads. The application
of the brake pads will cause the rotation of the wheels to slow or stop, depending on how much brake pressure
is applied. The parking brakes carry out the same function except that they are mechanically actuated by a
cable that connects only to the rear brakes.
Brake Master Cylinder Compensator Ports
The purpose of the compensator ports in the brake master cylinder is to supply additional brake fluid from the
master cylinder reservoir when needed by the brake system due to brake lining wear and allow brake fluid to
return to the master cylinder reservoir when the brakes are released. The returning brake fluid creates a slight
turbulence in the master cylinder reservoir. This is a normal condition and indicates that the compensator
ports are not clogged. Clogged compensator ports may cause the brakes to hang up or not fully release.
Red Brake Warning Indicator
The red brake warning indicator alerts the driver to certain conditions that exist in the brake system. The
Instrument Cluster (IC) performs a bulb check when the ignition key is turned to the RUN position. The
conditions that cause the indicator to illuminate are low brake fluid level, the parking brake is applied or there
is a fault in the ABS (if the yellow ABS warning indicator is also illuminated). To diagnose red brake warning
indicator concerns, refer to Section 413-01 .
Principles of Operation 2175



Manual
Inspection And Verification
Material
Item Specification
High Performance DOT 3 WSS-M6C62-A or
Motor Vehicle Brake Fluid WSS-M6C65-A1
(Canada)
Verify the customer concern.
For parking brake concerns, refer to Section 206-05 .
For ABS concerns, refer to Section 206-09 .
For adjustable pedal concerns, refer to Section 206-06 .
For all other concerns, continue with the next step.
Brake fluid level and condition Parking brake switch

Brake master cylinder Brake fluid level switch
Brake master cylinder reservoir Wiring, terminals or
Brake booster connectors
Brake booster check valve
Brake booster vacuum hose
Brake hoses and tubes
Brake caliper, guide pins and
anchor plate
Brake disc
Brake pads
Brake pedal, bracket and booster
linkage
Aftermarket modifications
Inspection And Verification 2177

3. Visually inspect the suspension system and tires for obvious signs of wear or damage.
For suspension system concerns, refer to Section 204-00 .
For tire concerns, refer to Section 204-04 .
5. If the cause is not visually evident, GO to Symptom Chart - Brake System or GO to Symptom Chart -
NVH in this section.


Manual
Symptom Chart
Symptom Chart - Brake System
Symptom Chart - Brake System
Symptom Chart - NVH
Symptom Chart - NVH

elimination type of diagnostic approach to pinpoint the responsible system. If ths not the causal system for the
Vibration when the brakes are applied
Brake disc(s)
Suspension components
Brake vibration/shudder - occurs when the brake pedal is released
Brake drag
GO to Symptom Chart - Brake System .
Rear brake noise - occurs when the brake pedal is unapplied
Parking brake component
INSPECT the parking brake components. REFER to Section 206-05 .
Rattling noise
Caliper guide pins or guide pin bolts
CHECK the caliper guide pins and guide pin bolts. REFER to Brake System Inspection in this
section.
Missing or damaged anti-rattle clips or springs
Symptom Chart 2179

CHECK the brake pads for missing clips or broken springs. INSTALL new components as necessary.
REFER to Section 206-03 for front disc brakes or Section 206-04 for rear disc brakes.
Loose brake disc shield
TIGHTEN the brake disc shield bolts to specification. REFER to Section 206-03 for front disc brakes
or Section 206-04 for rear disc brakes.
Squealing noise - occurs on first (morning) brake application
Brake pads
Acceptable condition. Caused by humidity and low brake pad temperature.
Squealing noise - a continuous squeal
Brake pads
INSPECT the brake pads. REFER to Brake System Inspection in this section.
Squealing noise - an intermittent squeal
Brake pads
Acceptable condition. Caused by cold, heat, water, mud or snow.
Groaning noise - occurs at low speeds with brake lightly applied (creeping)
Brake pads
Acceptable condition.
Grinding/moaning noise - continuous
Brake pads
Brake disc
INSPECT the brake pads, brake discs and attaching hardware. VERIFY brake components are within
specifications. REFER to Brake System Inspection in this section.
Symptom Chart 2180

Symptom Chart 2181


Manual
Pinpoint Tests
Pinpoint Test A: Vibration When the Brakes are Applied
Normal Operation
During moderate to heavy braking, noise from the Hydraulic Control Unit (HCU) and pulsation in the brake
pedal can be observed. Pedal pulsation coupled with noise during heavy braking or on loose gravel, bumps,
wet or snowy surfaces is acceptable and indicates correct functioning of the ABS. Pedal pulsation or steering
wheel nibble when the brakes are applied (frequency is proportioned to the vehicle speed) indicates a concern
with a brake or suspension component.
PINPOINT TEST A: VIBRATION WHEN THE BRAKES ARE APPLIED

A1 ROAD TEST THE VEHICLE - LIGHT BRAKING
Yes
Road test the vehicle. Warm the brakes by slowing the vehicle from 80 GO to A4 .
to 32 km/h (50 to 20 mph) using light brake force. At highway speeds
of 89-97 km/h (55-60 mph), apply the brake using light pedal force. No
Is there a vibration/shudder felt in the steering wheel, seat or brake GO to A2 .
pedal?
A2 ROAD TEST THE VEHICLE - MODERATE TO HEAVY
BRAKING
Yes
Road test the vehicle. At highway speeds of 89-97 km/h (55-60 mph), GO to A3 .
apply the brake using a moderate to heavy pedal force.
Is there a vibration/shudder? No
The concern is not
present at this time.
A3 CHECK ABS OPERATION
Yes
NOTE: During moderate to heavy braking, noise from the HCU and This is a normal
pulsation in the brake pedal can be observed. Pedal pulsation coupled operating condition of
with noise during heavy braking or on loose gravel, bumps, wet or the ABS.
snowy surfaces is acceptable and indicates correct operation of the
ABS. Pedal pulsation or steering wheel nibble with the frequency No
proportional to vehicle speed indicates a concern with a brake or GO to A5 .
suspension component.
Road test the vehicle and apply the bres on a dry, firm surface, then
apply the brakes on a wet, snowy or loose surface (such as gravel).
Is the vibration/shudder only present on a wet, snowy or loose
surface?
A4 ISOLATE BRAKE VIBRATION
Pinpoint Tests 2182

NOTE: This test is not applicable to vehicles with drum-in-hat type Yes
parking brakes. For vehicles with drum-in-hat parking brakes, proceed GO to A7 .
to the next test step. For all other vehicles, apply the parking brake to
identify if the problem is in the front or rear brake. No
Apply the parking brake to identify if the problem is in the front or rear GO to A5 .
brake. At highway speeds of 89-97 km/h (55-60 mph), lightly apply the
parking brake until the vehicle slows down. Release the parking brake
immediately after the test.
Is there a vibration/shudder?
A5 CHECK THE FRONT SUSPENSION
Yes
Check the front suspension. Refer to Section 204-00 . GO to A6 .
Are all the suspension components in satisfactory condition?
No
REPAIR or INSTALL
new components as
necessary. TEST the
system for normal
operation.
A6 CHECK THE FRONT BRAKE DISCS
Yes
Inspect the front brake discs. Refer to Brake System Inspection in this GO to A7 .
section.
Road test the vehicle. No
Is the vibration/shudder present? The concern has been
repaired.
A7 CHECK THE REAR SUSPENSION
Yes
Check the rear suspension. Refer to Section 204-00 . INSPECT the rear brake
Are all the suspension components in satisfactory condition? discs. REFER to Brake
System Inspection in
this section.
No
REPAIR or INSTALL
new components as
necessary. TEST the
system for normal
operation.
PINPOINT TEST A: VIBRATION WHEN THE BRAKES ARE APPLIED 2183

PINPOINT TEST A: VIBRATION WHEN THE BRAKES ARE APPLIED 2184


Manual
Component Tests
Brake Booste
1. Disconnect the brake booster vacuum sensor/check valve from the brake booster and connect a
suitable vacuum/pressure tester to the booster side of the vacuum sensor/check valve.
2. Apply the parking brake, start the engine and place the transmission in NEUTRAL.
Allow the engine to reach normal operating temperature.
3. NOTE: Subtract approximately 3.38 kPa (1 in-Hg) from the specified reading for every 304.8 m
(1,000 ft) of elevation above sea level.
Verify that vacuum is available at the vacuum sensor/check valve with engine running at normal idle
speed.
The vacuum gauge should read between 51-74 kPa (15-22 in-Hg).
If specified vacuum is available, stop the engine, connect the vacuum sensor/check valve and
continue with Step 5.
If specified vacuum is not available, continue with Step 4.
4. Disconnect the vacuum sensor/check valve from the vacuum hose and verify that the specified
vacuum is available at the hose with the engine at idle speed and the transmission in NEUTRAL.
If specified vacuum is available, stop the engine, install a new vacuum sensor/check valve
and continue with Step 5.
If specified vacuum is not available, stop the engine, connect the vacuum hose to the vacuum
sensor/check valve and refer to Section 303-00 to diagnose the no/low vacuum condition.
5. Apply the brake pedal several times to exhaust all vacuum from the system.
6. Apply the brake pedal and hold it in the applied position. Start the engine and verify that the brake
pedal moves downward after the engine starts.
If the brake pedal moves, the brake booster is operating correctly.
If the brake pedal does not move, install a new brake booster. Refer to Section 206-07 .
7. Operate the engine a minimum of 20 seconds at idle. Stop the engine and let the vehicle stand for 10
minutes, then apply the brake pedal. The brake pedal feel should be the same as that noted with the
engine operating.
If the brake pedal feels hard (no power assist), install a new brake booster vacuum
sensor/check valve and retest.
If condition still exists, install a new brake booster. Refer to Section 206-07 .
If the brake pedal feels the same as noted with the engine operating, the vacuum sensor/check
valve is functioning properly.
Brake Master Cylinder - Bypass Condition
1. Inspect the master cylinder. Refer to Brake System Inspection in this section.
Component Tests 2185

2. Disconnect the brake tubes from the master cylinder.
3. Plug the outlet ports of the master cylinder.
4. NOTE: Make sure that the outlet port plugs do not show signs of leakage.
Lightly apply the brakes and hold for 10 seconds. Release the brakes and then reapply with heavy
force. If brake pedal height cannot be maintained, the brake master cylinder has an internal leak and a
new brake master cylinder must be installed.
If brake pedal height is maintained, reinstall brake tubes and tighten to specifications. Refer to
Specifications in this section. After installation, bleed the brake system. Refer to Brake
System Bleeding in this section.
Brake Master Cylinder - Compensator Port
1. Inspect the master cylinder. Refer to Brake System Inspection in this section.
2. With the vehicle in NEUTRAL, position it on a hoist. Refer to Section 100-02 .
3. Apply and release the brakes.
4. With the brakes released, attempt to rotate each wheel and check for any brake drag.
If an excessive amount of brake drag exists at multiple wheels, continue to Step 5.
If an excessive amount of brake drag exists at only one wheel, it indicates a possible seized
brake caliper, brake wheel cylinder or parking brake component. Repair or install new
components as necessary.
5. Check the brake stoplamp switch and the brake pedal free play to verify that the brake pedal is not
partially applied.
6. Loosen the brake master cylinder nuts and position the brake master cylinder away from the brake
booster.
7. With the brakes released, attempt to rotate each wheel and check for any brake drag.
If the brake drag is no longer present, install a new brake booster. Refer to Section 206-07 .
If the brake drag is still present, install a new master cylinder. Refer to Section 206-06 .


Brake System Inspection
Material
Item Specification
Metal Brake Parts Cleaner -
PM-4-A or PM-4-B (US); CPM-4
(Canada)
Dielectric Compound
XG-3-A
Brake Pads
NOTE: It is not required to install new brake pads when the brake discs are machined.
1. Inspect the brake pad friction material for contamination.

If the friction material shows evidence of contamination, install new brake pads. For
additional information, refer to Section 206-03 for front brake pads or Section 206-04 for rear
brake pads.
Inspect and measure the thickness of the brake pad friction material. For additional information, refer to
Minor surface cracks do not require pad replacement, however, if there are missing chunks or
cracks in the lining through to the backing plate, install new brake pads. For additional information,
refer to Section 206-03 for front brake pads or Section 206-04 for rear brake pads.
If the thickness of the friction material is less than the specified thickness, install new brake pads.
For additional information, refer to Section 206-03 for front brake pads or Section 206-04 for rear
brake pads.
If the friction material shows taper wear that is not within specifications, install new brake pads and
verify the caliper guide pins are functioning correctly. For additional information, refer to Brake
Caliper Guide Pins inspection.
Brake Discs
NOTICE: Using an impact tool without a torque socket will lead to unevenly tightened wheel nuts. This
causes brake disc on-vehicle lateral runout and brake roughness.
1. Inspect the brake discs and measure the brake disc thickness. Record the measurement. Refer to
If the brake disc is cracked or otherwise damaged, install a new brake disc. For additional
information, refer to Section 206-03 for front brakes or Section 206-04 for rear brakes.
If the measurement is below the minimum thickness specification, install a new brake disc.
For additional information, refer to Section 206-03 for front brakes or Section 206-04 for rear
Brake System Inspection 2188

brakes.
If the diagnosis has revealed vibration in the steering wheel, seat or pedal while braking that
varies with vehicle speed, machine the brake disc. Heavily scored brake discs, similar to that
caused by pads worn down to the backing plate, should also be machined. In order to
machine, discs must be above the minimum thickness specification. For additional
information, refer to Specifications and Brake Disc Machining in this section.
Brake Calipers
1. Inspect the brake calipers for leaks, damage to seals and piston corrosion or binding.
If the brake caliper is leaking or otherwise damaged, install a new brake caliper. For
additional information, refer to Section 206-03 for front brake calipers or Section 206-04 for
rear brake calipers.
Brake Caliper Guide Pins
1. The guide pins should slide with a reasonable amount of hand force. If the brake pads show taper
wear or the guide pins are difficult to move, carry out the following steps.
Disassemble the brake caliper guide pins and inspect the guide pins and guide pin bores for
wear, damage and corrosion. If the bore is worn or damaged, replace the damaged
component.
Use a wire brush, rolled-up sandpaper or emery cloth to remove all corrosion and foreign
material from the caliper guide pin bores. Clean any remaining foreign material from the
bores with brake parts cleaner and compressed air.
Assemble the caliper seals, boots and guide pins. Use an ample amount of the specified
grease to lubricate the bores and guide pins.
Inspect the brake pads. For additional information, refer to Brake Pads inspection in this
section.
Brake Flexible Hoses and Tubes
NOTICE: Never use copper tubing. It is subject to fatigue, cracking and corrosion, which may result in
brake tube failure.
NOTE: Double-wall steel tubing is used throughout the brake hydraulic system. All brake tube fittings must
be correctly double flared to provide strong, leakproof connections. When bending tubing to fit the underbody
or rear axle contours, be careful not to kink or crack the tube.
1. Inspect brake tubes for corrosion, cracks, leaks or any other signs of damage.
If a section of the brake tube is damaged, the entire section must be installed with a new tube
of the same type, size, shape and length.
When installing the hydraulic brake tubing, hoses or connectors, tighten all connections to
specifications. After installation, bleed the brake system. For additional information, refer to
Brake System Bleeding in this section.
2. Inspect the brake flexible hoses for cracks, leaks and swelling during brake application or any other
signs of damage.
Install a new brake flexible hose if the hose shows signs of softening, cracking or other
damage. For additional information, refer to Section 206-03 for the front brake flexible hose
or Section 206-04 for the rear brake flexible hose.

Brake Master Cylinder
NOTE: During normal operation of the brake master cylinder, the fluid level in the brake master cylinder
reservoir will fall during brake application and rise during release. The returning brake fluid creates a slight
turbulence in the master cylinder reservoir. This is a normal condition and indicates that the compensator
ports are not clogged. Clogged compensator ports may cause the brakes to hang up or not fully release. The
net fluid level (such as after brake application and release) will remain unchanged. Fluid level will decrease
with pad wear.
NOTE: A trace of brake fluid will exist on the booster shell below the master cylinder mounting flange. This
results from the normal lubricating action of the master cylinder bore and seal.
1. Inspect the brake master cylinder for fluid leaks.

Install a new master cylinder or brake fluid reservoir if signs of excessive leaking are present.
To check for correct brake master cylinder operation, refer to Component Tests in this
section.
Brake Booster
1. Inspect the brake booster for excessive corrosion or damage. Inspect the vacuum hoses for leaks and
kinks.
Install a new brake booster if signs of excessive corrosion or damage is found. For additional
Repair or replace vacuum hoses as necessary.
To check for correct brake booster operation, refer to Component Tests in this section.

Brake Disc Machining
NOTE: Do not use a bench lathe to machine the brake discs. Use an on-vehicle brake lathe only. Read the
entire operating manual and/or view the video shipped with the lathe before installing, operating or repairing
the lathe.
NOTE: An on-vehicle brake lathe with an automatic runout adjustment feature is preferred. However, if the
lathe is not self adjusting, the lathe oscillation must be adjusted using a dial indicator. The total indicated
runout target is 0.000 mm (0.000 in). The maximum iicated runout should be no more than 0.050 mm (0.002
in). If the runout adjustment (automatic or manual) is carried out correctly prior to machining, then the final
brake disc runout will be within specification and a runout measurement is not necessary after machining.
NOTE: Lateral runout and disc thickness variation measurements are not required because correct adjustment
of the on-vehicle brake lathe will make sure that these dimensions are within specification.
2. NOTICE: Do not allow the caliper to hang from the brake hose or damage to the hose may
occur.
Remove the bolts and position the brake caliper or brake caliper and anchor plate assembly aside, as
required.
Support the brake caliper using mechanic's wire.
3. Install the hub adapter using:

four wheel nuts on a 4-stud wheel hub.
five wheel nuts on a 5-stud wheel hub.
six wheel nuts on a 6-stud wheel hub.
four wheel nuts on a 7- or 8-stud wheel hub.
five wheel nuts on a 10-stud wheel hub.
4. Install the cutting lathe.
5. If the lathe is not self adjusting, adjust the lathe oscillation using a dial indicator. The total indicated
runout target is 0.000 mm (0.000 in). The maximum indicated runout should be no more than 0.050
mm (0.002 in).
6. Center the cutting head, adjust the cutting bits and install the chip deflector/silencer.
7. NOTE: The depth of the cut should be between 0.10 and 0.40 mm (0.004 and 0.015 in). Lighter cuts
will cause the bit to heat up and wear faster. Heavier cuts will cause poor brake disc surface finish.
Machine the brake disc.
8. Remove the lathe and the silencer.
9. Remove the wheel nuts and hub adapter.
10. Remove the metal shavings.
Brake Disc Machining 2191

11. Measure the brake disc thickness.

If the measurement is below the minimum specification, install a new brake disc. For
additional information, refer to Section 206-03 for front disc brakes or Section 206-04 for rear
disc brakes.
12. NOTE: It is not required to install new brake pads if friction material is within specifications. For
additional information, refer to Specifications in this section.
Position the brake caliper or brake caliper and anchor plate assembly.
Install the bolts.

For fastener torque specifications, refer to Section 206-03 for front disc brakes or Section
206-04 for rear disc brakes.
Brake Disc Machining 2192

SECTION 206-00: Brake System - General Informat 2011 Expedition, Navigator Workshop Manual
Component Bleeding
Material
Item Specification
(Canada)
Master Cylinder
WARNING: Carefully read cautionary information on product label. For EMERGENCY

MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products
call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet
(MSDS) if available. Failure to follow these instructions may result in serious personal injury.
WARNING: Do not allow the brake master cylinder to run dry during the bleeding operation.
Master cylinder may be damaged if operated without fluid, resulting in degraded braking performance.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If
brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.
NOTE: When a new brake master cylinder has been installed, or the system is emptied or partially emptied, it
should be primed to prevent air from entering the system.
1. Disconnect the brake tubes from the master cylinder.
2. Install short brake tubes with the ends submerged in the brake master cylinder reservoir.
Component Bleeding 2193

3. Fill the brake master cylinder reservoir with clean, specified brake fluid.
4. Have an assistant pump the brake pedal until clear fluid flows from both brake tubes, without air
bubbles.
5. Remove the short brake tubes and install the brake outlet tubes.
6. Bleed the brake system. For additional information, refer to Brake System Bleeding in this section.
Brake Caliper

1. NOTE: It is not necessary to do a complete brake system bleed if only the brake caliper was
disconnected or installed new.
Remove the bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber
drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled
with clean, specified brake fluid.
2. Have an assistant pump the brake pedal at least 2 times and then hold firm pressure on the brake
pedal.
3. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains
pressure on the brake pedal, tighten the bleeder screw.
Repeat until clear, bubble-free fluid comes out.
Refill the brake master cylinder reservoir as necessary.
4. Remove the rubber hose and tighten the bleeder screw to specifications. For additional information,
refer to Specifications in this section.
Install the bleeder screw cap.


SECTION 206-00: Brake System - General Informat 2011 Expedition, Navigator Workshop Manual
Brake System Bleeding
Special Tool(s)

Material
Item Specification
(Canada)
Pressure

NOTE: The Hydraulic Control Unit (HCU) bleeding procedure must be carried out if the HCU or any
components upstream of the HCU are installed new.
NOTE: Pressure bleeding the brake system is preferred to manual bleeding.
1. Clean all dirt from the brake master cylinder filler cap and remove the filler cap.
Fill the brake master cylinder with clean specified brake fluid.
Brake System Bleeding 2196

2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of
pressure bleeding equipment. Follow the instructions of the equipment manufacturer when installing
the adapter.
Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose to
the fitting on the adapter.
3. NOTE: Make sure the bleeder tank contains enough clean, specified brake fluid to complete the
bleeding operation.
Open the valve on the bleeder tank.
Apply 207-345 kPa (30-50 psi) to the brake system.
4. Remove the RH rear bleeder cap and place a box-end wrench on the bleeder screw. Attach a rubber
drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially
filled with clean, specified brake fluid.
5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten
the RH rear bleeder screw and remove the rubber hose.
Tighten to specifications. For additional information, refer to Specifications in this section.
6. Continue bleeding the system, going in order from the LH rear bleeder screw to the RH front bleeder
screw ending with the LH front bleeder screw.
7. Release the bleeder tank pressure and close the bleeder tank valve. Remove the tank hose from the
adapter and remove the adapter from the brake fluid reservoir.
Manual


NOTE: The HCU bleeding procedure must be carried out if the HCU or any components upstream of the
HCU are installed new.
1. Clean all dirt from the brake master cylinder filler cap and remove the filler cap.
Fill the brake master cylinder with clean specified brake fluid.
2. Remove the bleeder screw cap and place a box-end wrench on the RH rear bleeder screw. Attach a
rubber drain hose to the RH rear bleeder screw and submerge the free end of the hose in a container
partially filled with clean, specified brake fluid.
3. Have an assistant pump the brake pedal at least 3 times and then hold firm pressure on the brake
pedal.
4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal, tighten the RH rear bleeder screw.
Repeat until clear, bubble-free fluid comes out.
Refill the brake master cylinder reservoir as necessary.
5. Remove the rubber hose and tighten the bleeder screw to specifications. For additional information,
6. Repeat Steps 2 through 5 for the LH rear, RH front and LH front bleeder screws in this order.
Hydraulic Control Unit (HCU)
NOTE: The HCU bleeding procedure must be carried out if the HCU or any components upstream of the

HCU are installed new.
1. Follow the Pressure Bleeding or Manual Bleeding procedure steps to bleed the system.
2. Connect the scan tool and follow the ABS Service Bleed instructions.
3. Repeat the Pressure Bleeding or Manual Bleeding procedure steps to bleed the system.

SECTION 206-03: Front Disc Brake 2011 Expedition, Navigator Workshop Manual
Material

Capacity
(Canada)
CPM-4 (Canada)
Item Specification
Brake Disc
Brake disc minimum thickness 32.0 mm (1.259 in)
Brake Pads

Brake caliper flow bolt 40 30 -
Brake caliper guide pin bolts 37 27 -
Brake flexible hose bracket-to-frame bolt 17 - 150
Brake flexible hose bracket-to-spindle bolt 30 22 -
Brake tube fitting 17 - 150


Front Disc Brake
The front brake disc system consists of the following components:
Brake pads
Brake caliper anchor plate
Brake caliper
Brake disc
Brake disc shield
Brake flexible hose
When mechanical force is applied by the driver to the brake pedal, the force is converted into hydraulic
pressure by the master cylinder. The hydraulic force is directed to the disc brake calipers and transferred to the
brake pads. The brake pads are then forced against the brake friction surfaces by the brake caliper pistons. The
friction of the brake pads on the brake disc causes the slowing of wheel rotation and the vehicle.
Front Disc Brake 2202

Front Disc Brake
Front Disc Brake 2203

Disc Brake System - Exploded View
NOTE: Rear Wheel Drive (RWD) shown, Four-Wheel Drive (4WD) similar.

1 - Brake caliper guide pin bolt (part of kit 2C150)
2 2B120 RH/ 2B121 Brake caliper
LH
3 2001 Brake disc pad (2 required)
4 - Spring clip (part of 2C321) (2 required)
6 2B292 Brake caliper anchor plate
7 1125 Brake disc
8 W505252 Brake disc shield bolt (3 required)
9 2K004 RH/ 2K005 Brake disc shield
LH
10 385116 Brake caliper flow bolt
11 388949 Copper washers
12 W506423 Brake flexible hose bracket-to-wheel knuckle
bolt
13 W712215 Brake flexible hose bracket-to-frame bolt
Disc Brake System - Exploded View 2204

14 - Brake tube fitting (part of 2263 RH/ 2264 LH)

15 d> Wheel speed sensor harness
16 2078 Brake flexible hose

Brake Pads
Material
Item Specification
(Canada)
Removal

WARNING: Always install new brake shoes or pads at both ends of an axle to reduce the possibility
of brakes pulling vehicle to one side. Failure to follow this instruction may result in uneven braking and
1. Check the brake fluid level in the brake master cylinder reservoir.
If necessary, remove fluid until the brake master cylinder reservoir is half full.
3. NOTICE: Do not allow the caliper to hang from the brake hose or damage to the hose can
occur.
Remove the 2 brake caliper guide pin bolts and position the caliper aside.
4. Remove the brake pads and the 4 spring clips.

Discard the spring clips.
Installation
1. NOTE: Protect the pistons and boots when compressing the piston into its bore.
Using a C-clamp and a worn brake pad, compress the disc brake caliper pistons into the brake caliper
bore.
Brake Pads 2206

2. NOTE: One brake disc pad kit contains the pads required for both the RH and LH side.
Install the new spring clips and brake pads.
3. NOTE: Tighten the lower caliper guide pin bolt first.
Position the brake caliper on the brake caliper anchor plate and install the 2 guide pin bolts.
Apply brakes several times to verify correct brake operation.
5. Fill the master cylinder with clean, specified brake fluid.
Brake Pads 2207

Brake Caliper
Material
Item Specification
(Canada)
Removal

2. Remove the brake caliper flow bolt and discard the 2 copper washers.
3. Remove the 2 brake caliper guide pin bolts and the brake caliper.
Installation
1. Using 2 new copper washers, position the brake flexible hose on the brake caliper and install the
brake caliper flow bolt.
2. NOTE: Tighten the lower caliper guide pin bolt first.
Position the brake caliper on the brake caliper anchor plate and install the 2 guide pin bolts.
3. Bleed the brake caliper. For additional information, refer to Component Bleeding in Section 206-00 .
Brake Caliper 2208

Brake Caliper 2209

Brake Caliper Anchor Plate
Material
Item Specification
(Canada)
1. Remove the brake pads. For additional information, refer to Brake Pads in this section.
2. Remove and discard the 2 brake caliper anchor plate bolts.

3. Clean any rust or foreign material from the anchor plate and wheel knuckle.
Use specified parts cleaner to clean mating surfaces.
Brake Caliper Anchor Plate 2210

Brake Disc
Material
Item Specification
(Canada)
Removal
damage to the hose can occur.
Remove the 2 brake caliper anchor plate bolts and position the caliper and anchor plate assembly
aside.
Support the caliper and anchor plate assembly using mechanic's wire.
3. Remove the front brake disc from the wheel hub.
Installation
1. Clean any rust or foreign material from the brake disc and wheel hub.
Use specified parts cleaner to clean the front brake disc and hub surfaces.
2. Install the brake disc on the wheel hub.
3. Position the brake caliper and anchor plate assembly on the wheel knuckle and install 2 new bolts.
Brake Disc 2211

Brake Disc 2212

Brake Disc Shield
1. Remove the brake disc. For additional information, refer to Brake Disc in this section.
2. Remove the 3 brake disc shield bolts and the brake disc shield.
Brake Disc Shield 2213

Brake Flexible Hose
Material
Item Specification
(Canada)

Use new copper washers.
2. Disconnect the brake tube fitting from the brake flexible hose.
3. Detach the wheel speed sensor harness pin-type retainer from the brake flexible hose bracket.
4. Detach the brake flexible hose retainer from the wheel speed sensor harness.
5. Remove the brake flexible hose-to-wheel knuckle bolt.

6. Remove the brake flexible hose-to-frame bracket bolt and the brake flexible hose.
7. To install reverse the removal procedure.

Bleed the brake caliper. For additional information, refer to Component Bleeding in Section
206-00 .
Brake Flexible Hose 2214


SECTION 206-04: Rear Disc Brake 2011 Expedition, Navigator Workshop Manual
Material

Capacity
High Performance DOT 3 WSS-M6C62-A or 1420 ml
(Canada)
CPM-4 (Canada)
Item Specification
Brake Disc
Brake disc minimum thickness 20.0 mm (0.787 in)
Brake Pads

Brake caliper bleed screw 16 - 142
Brake caliper guide pin bolts 38 28 -
Brake flexible hose bracket bolt 18 - 159
Brake hose flow bolts 40 30 -
Brake tube fitting 18 - 159


Rear Disc Brake
The rear disc brake system consists of the following components:
Brake caliper anchor plate

Brake caliper
Brake disc
Brake flexible hose
Brake pads
When mechanical force is applied by the driver to the brake pedal, the force is converted into hydraulic
pressure by the master cylinder. The hydraulic force is directed to the disc brake calipers and transferred to the
brake pads. The brake pads are then forced against the brake friction surfaces by the brake caliper pistons. The
friction of the brake pads on the brake disc causes the slowing or stopping of wheel rotation and the vehicle.
Rear Disc Brake 2218

Rear Disc Brake
Rear Disc Brake 2219

Disc Brake System - Exploded View
Part
1 2C026 Brake disc
2 2B582 Brake caliper anchor plate kit
3 - Brake pad (part of kit 2200)
4 W707292 Brake caliper anchor plate bolts (2 required)
5 - Brake caliper (part of kit 2552 RH/2553 LH)
6 - Brake caliper guide pin bushing (2 required) (part of kits
2C534, 2552, 2553 and 2200)
7 2C563 Bleeder screw and cap (also part of kits 2552 and 2553)
8 - Brake caliper guide pin (2 required) (part of kit 2C534)
9 - Brake caliper guide pin cap (2 required) (part of kit
2C534)


Brake Pads
Material
Item Specification
(Canada)
CPM-4 (Canada)
Removal

WARNING: Always install new brake shoes or pads at both ends of an axle to reduce the possibility
of brakes pulling vehicle to one side. Failure to follow this instruction may result in uneven braking and
NOTICE: Do not spill brake fluid onto painted or plastic surfaces or damage to surface may occ. If
If required, remove the fluid until the brake master cylinder reservoir is half full.
3. NOTICE: Do not allow the brake caliper to hang by the flexible brake hose or damage to the
hose may occur.
Remove the 2 brake caliper guide pin caps and bolts and position the caliper and brake pad assembly
aside.

Remove and discard the guide pin bushings.
Inspect the guide pin threads for damage, install new guide pin(s) as necessary.
4. Remove the brake pads from the caliper.
5. Inspect the brake pads for wear or contamination and install new pads as necessary. For additional
Brake Pads 2222

information, refer to General Procedures in Section 206-00 .
6. Using a C-clamp and a worn brake pad, press the piston into the caliper.
7. Inspect the brake disc and resurface or install a new brake disc as necessary. For additional
Installation
1. Using specified brake parts cleaner, dry and inspect the brake caliper anchor plate. Apply equal
amounts of the supplied yellow lubricant to the 4 brake pad contact points on the anchor plate as
shown.
2. NOTICE: Do not apply lubricant to guide pin threads or incorrect tightening of the guide pins
may result.
Install new brake hardware as follows:
Apply equal amounts of the supplied white lubricant to the inside of the guide pin bushings.
Install the guide pin bushings into the caliper bores.
Install the guide pins into the bushings.
3. Install the brake pads to the caliper.
4. Position the caliper onto the anchor plate and install the 2 brake caliper guide pin bolts.
Clean and dry guide pin threads as necessary.
7. Apply the brake several times to verify correct brake operation.
Brake Pads 2223

Brake Pads 2224

Brake Caliper
Material
Item Specification
(Canada)

NOTICE: Do not spill brake fluid onto painted or plastic surfaces or damage to surface may occur. If
2. Remove the brake hose flow bolt and disconnect the hose.
Remove and discard the copper washers.
3. Remove the 2 brake caliper guide pin caps and bolts.

Inspect the guide pin threads for damage, install a new guide pin(s) as necessary.
Clean and dry guide pin threads as necessary.
4. Remove the brake caliper and remove the brake pads from the caliper.
5. Inspect the disc brake caliper dust boot for leaks and/or damage.
If leaks or damage are found, install a new brake caliper.
6. NOTICE: Do not apply lubricant to guide pin threads or incorrect tightening of the guide pins
may result.
Brake Caliper 2225

Install new guide pin bushings.

Apply supplied white lubricant to the inside of the guide pin bushings.
7. Bleed the brake caliper. For additional information, refer to Section 206-00 for Component Bleeding.
Brake Caliper 2226

Brake Caliper Anchor Plate
Material
Item Specification
(Canada)
CPM-4 (Canada)

If required, remove the fluid until the brake master cylinder reservoir is half full.
3. NOTICE: Do not allow the caliper and brake pad assembly to hang from the brake hose or
damage to the hose may occur.
Remove the 2 brake caliper guide pin caps and bolts and position the caliper and brake pad assembly
aside.

Inspect the guide pin threads for damage and inspect the guide pin bushings for wear/damage.
Install a new guide pin(s) and bushing(s) as necessary.
4. Remove the 2 brake caliper anchor plate bolts and the brake caliper anchor plate.
Inspect the caliper anchor plate bolt threads for damage and foreign material. Install cleaned
and dried anchor plate bolts or install new as necessary.
5. Using specified brake parts cleaner, dry and inspect the brake caliper anchor plate. Apply equal

amounts of the supplied yellow lubricant to the 4 brake pad contact points on the anchor plate as
indicated.

Apply the brake several times to verify correct brake operation.

Brake Disc
2. NOTICE: Do not allow the brake caliper and anchor plate assembly to hang by the flexible
brake hose or damage to the hose may occur.
Remove the brake caliper anchor plate bolts and position the anchor plate and caliper assembly aside.
Support the caliper and anchor plate assembly with mechanic's wire.
Inspect the brake caliper anchor plate bolt threads for damage and foreign material. Install
cleaned and dried anchor plate bolts or install new as necessary.
3. NOTE: If the brake disc binds on the parking brake shoe, remove the adjustment hole access plug and
contract the parking brake shoe.
Remove the brake disc.
4. Inspect the brake disc and resurface or install a new brake disc as necessary. For additional
Brake Disc 2229

Brake Flexible Hose

1 - Brake tube fitting (part of 2265)
2 - Brake flexible hose bracket bolt
3 385116 Brake caliper flow bolt
4 2149 Copper washers (2 required)
5 2282 Brake flexible hose

1. Remove the wheel ande. For additional information, refer to Section 204-04 .
Install new copper washers.
3. Disconnect the brake tube fitting from the brake flexible hose.
4. Remove the brake flexible hose bracket bolt.


Bleed the brake caliper. For additional information, refer to Section 206-00 .

SECTION 206-05: Parking Brake and Actuation 2011 Expedition, Navigator Workshop Manual
Material

Capacity
Dielectric Compound
XG-3-A
Front parking brake cable P-clip-to-frame bolt 18 159
Parking brake control assembly bolts 20 177
Parking brake release handle bolt 3 27
Rear parking brake cable-to-crossmember bolt 18 159
Wire form bracket bolt 18 159

Parking Brake
The parking brake and actuation system consists of the following components:
Parking brake cables

Parking brake control
Parking brake shoes
Red brake warning indicator
The parking brake system is a foot-operated/cable-actuated system that applies a drum-in-hat assembly within
each rear brake disc. A red brake warning indicator is located in the instrument cluster and will illuminate
when the system is actuated to alert the driver that the parking brakes are applied.
Parking Brake 2233

Parking Brake
Parking Brake System
When the parking brake control is pressed, tension is applied to the front parking brake cable. This tension
pulls on the RH rear parking brake cable, which is attached to the RH rear parking brake shoe actuator and
applies the RH rear brake shoes. At the same time, the tension in the RH rear cable causes the RH rear cable
conduit to attempt to straighten out. This straightening effect causes the RH rear cable conduit to pull on the
LH rear parking brake cable, which is attached to the LH rear parking brake shoe actuator and applies the LH
rear brake shoes.
Mechanical
Parking brake cable(s)
Parking brake control release
handle
Parking brake shoes and
hardware
4. If the cause is not visually evident, verify the symptom and GO to Symptom Chart .
Symptom Chart
Symptom Chart
Parking Brake 2234

Pinpoint Tests
Pinpoint Test A: The Parking Brake Does Not Apply
Normal Operation
When the parking brake control pedal is pressed the pedal should move a short distance, with more pressure
needed to apply the pedal as it gets closer to the floor, until the parking brake shoes are fully applied. When
the parking brake control is pressed, tension is applied to the front parking brake cable. This tension pulls on
the RH rear parking brake cable, which is attached to the RH rear parking brake shoe actuator and applies the
RH rear brake shoes. At the same time, the tension in the RH rear cable causes the RH rear cable conduit to
attempt to straighten out. This straightening effect causes the RH rear cable conduit to pull on the LH rear
parking brake cable, which is attached to the LH rear parking brake shoe actuator and applies the LH rear
brake shoes.

Parking brake cable(s)
Parking brake shoes and hardware
PINPOINT TEST A: THE PARKING BRAKE DOES NOT APPLY

A1 CHECK THE PARKING BRAKE CONTROL
Yes
Press the parking brake control pedal. GO to A2 .
Does the parking brake control pedal move?
No
GO to A5 .
A2 CHECK FOR BROKEN CABLES
Yes
NOTE: Have an assistant press and release the GO to A3 .
parking brake pedal to help isolate disconnected
cables or cables that do not move. No
Inspect the following items for damage and CONNECT the cable(s) or INSTALL a new
correct connections. parking brake component(s) as necessary.
Front cable and conduit TEST the system for normal operation.
LH rear cable and conduit
RH rear cable and conduit
Rear cable brackets
Are the cables in good condition?
A3 CHECK THE PARKING BRAKE SHOES,
ACTUATOR LEVERS AND HARDWARE
Yes
Remove the rear brake disc, refer to Section GO to A4 .
206-04 . Inspect the parking brake shoes, actuator
levers and hardware. No
Are the parking brake shoes, actuator levers INSTALL new components as necessary.
and hardware in good condition? REFER to Parking Brake Shoes in this


operation.
A4 CHECK THE PARKING BRAKE SHOE
ADJUSTMENT
Yes
Check the parking brake shoe adjustment. Refer to INSTALL a new parking brake control.
Parking Brake Shoe Adjustment in this section. REFER to Parking Brake Control in this
Are the parking brake shoes adjusted to section. TEST the system for normal
specification? operation.
No
ADJUST the rear parking brake shoes.
REFER to Parking Brake Shoe Adjustment
in this section.
A5 ISOLATE THE PARKING BRAKE CONTROL
AND FRONT PARKING BRAKE CABLE
Yes
Disconnect the front parking brake cable from the GO to A6 .
LH rear parking brake cable at the cable union.
No
GO to A7 .
Press the parking brake control pedal.

Does the parking brake control pedal move?
A6 ISOLATE THE REAR PARKING BRAKE
CABLES
Yes
Disconnect the rear parking brake cables from the INSPECT the parking brake shoes, hardware
parking brake actuating levers. and backing plate. INSTALL new
While holding the cable conduit, attempt to slide components as necessary. REFER to Parking
the cable inside the conduit. Brake Shoes in this section. TEST the system
Does the cable slide freely inside the conduit? for normal operation.
No
INSTALL new rear brake cable(s). REFER
to Parking Brake Cable - Rear, LH or
Parking Brake Cable - Rear, RH in this
operation.
A7 ISOLATE THE FRONT PARKING BRAKE
CABLE
Yes
Disconnect the front parking brake cable and INSTALL a new parking brake control.
conduit from the parking brake control. REFER to Parking Brake Control in this
While holding the cable conduit, attempt to slide section. TEST the system for normal
the cable inside the conduit. operation.
PINPOINT TEST A: THE PARKING BRAKE DOES NOT APPLY 2236

Does the cable slide freely inside the conduit?

No
INSTALL a new front parking brake cable.
Pinpoint Test B: The Parking Brake Will Not Release and/or Parking Brake Shoes Drag
Normal Operation
When the parking brake release handle is pulled, the ratchet mechanism and return spring in the parking brake
control release the tension on the parking brake cables and conduits. The springs on both rear cables provide
the force necessary to return the parking brake shoes to their released position.

Parking brake control release handle
Parking brake shoes and hardware

PINPOINT TEST B: THE PARKING BRAKE WILL NOT RELEASE AND/OR PARKING BRAKE SHOES DRAG

B1 CHECK THE PARKING BRAKE
CONTROL RELEASE HANDLE AND
CABLE
Yes
Verify that the release handle and cable GO to B2 .
are connected to the parking brake
control. No
Are the release handle and cable CONNECT the handle and cable, then TEST the
connected? system for normal operation.
B2 CHECK THE REAR PARKING BRAKE
CABLES
Yes
Disconnect the RH cable from the LH GO to B3 .
conduit equalizer, then disconnect the LH
cable from the front cable. No
INSTALL a new rear brake cable(s). REFER to
Parking Brake Cable - Rear, LH or Parking Brake
Cable - Rear, RH in this section. TEST the system for
normal operation.
Disconnect the rear parking brake cables

from the parking brake actuating levers.
While holding the rear cable conduit,
attempt to slide the rear cable inside the

conduit.
Does the cable slide freely inside the
conduit?
B3 CHECK THE REAR PARKING BRAKE
SHOES AND HARDWARE
Yes
Remove the rear brake disc. Refer to GO to B4 .
Section 206-04 .
Inspect the parking brake shoes, hardware No
and backing plate. INSTALL new components as necessary. TEST the
Are the shoes, hardware and backing system for normal operation.
plate in good condition?
B4 ISOLATE THE FRONT PARKING
BRAKE CABLE
Yes
Press the retaining tabs and disconnect the INSTALL a new parking brake control. REFER to
front parking brake conduit from the Parking Brake Control in this section. TEST the
parking brake control bracket. system for normal operation.
Push the front parking brake conduit
grommet through the body. No
Verify that the front cable conduit can INSTALL a new front cable. TEST the system for
slide freely on the cable. normal operation.
Does the conduit slide freely on the
cable?
PINPOINT TEST B: THE PARKING BRAKE WILL NOT RELEASE AND/OR PARKING BRAKE 2238
SHOES DRA
Parking Brake Cable Tension Release
1. Remove the LH cowl side trim panel. For additional information, refer to Section 501-05 .
2. With the help of an assistant, release the parking brake cable tension by pulling down on the
intermediate cable at the cable-to-cable union until the parking brake control sector rotates to its stop
and a 4 mm (0.15 in) x 150 mm (5.9 in) retainer pin can be inserted.
3. To reload the tension on the parking brake cable, follow the release procedure in reverse.
Make sure the cable tension is reloaded slowly.
Parking Brake Cable Tension Release 2239

Parking Brake Shoe Adjustment
Special Tool(s)
Brake Adjusting Gauge

1. NOTE: Make sure the parking brake is fully released.
Using the release handle, release the parking brake control.
2. Remove the rear brake disc. For additional information, refer to Section 206-04 .
3. Using the Brake Adjusting Gauge, measure the inside diameter of the drum portion of the rear brake
disc and set the locking screw.
Record the measurement.
4. Place the Brake Adjusting Gauge over the widest diameter of the parking brake shoes.
5. Adjust the parking brake shoe clearance to 0.45 mm (0.02 in) less than the inside diameter of the
drum portion of the rear brake disc.
Rotate the parking brake shoe adjuster to achieve the correct parking brake shoe-to-brake disc
clearance.
6. Install the rear brake disc. For additional information, refer to Section 206-04 .
7. Test the parking brake for normal operation.
Parking Brake Shoe Adjustment 2240

Parking Brake Shoe Adjustment 2241

Parking Brake Control

1 2783 Parking brake release handle
2 W707628 Parking brake release handle bolt
3 W704522 Parking brake control assembly bolt (3 required)
4 2780 Parking brake control
5 - Parking brake switch electrical connector (part of
14489)
1. Relieve tension on the parking brake cable system. For additional information, refer to Parking Brake
Cable Tension Release in this section.
2. Remove the front door scuff plate. For additional information, refer to Interior Trim - Exploded View
in Section 501-05 .
3. Remove the instrument panel steering column opening trim panel and if equipped, the instrument
panel lower cover. For additional information, refer to Instrument Panel - Exploded View in Section
501-12 .
4. Remove the parking brake release handle bolt.

5. Remove the retainer and the cowl trim panel. For additional information, refer to Interior Trim -
Exploded View in Section 501-05 .
6. Compress the 2 tabs and disconnect the parking brake release cable from the parking brake control
assembly.
Parking Brake Control 2242

7. Disconnect the parking brake release cable from the release lever and remove the parking brake
release handle.
8. Disconnect the parking brake switch electrical connector.
9. Remove the 3 parking brake control assembly bolts.

10. Position the parking brake control assembly onto the floor.
11. Disconnect the parking brake cable from the take-up spool.
12. Compress the 2 tabs, disconnect the parking brake cable from the control assembly and remove the
control assembly.


Parking Brake Cable - Front

1 W506423 Front park brake cable P-clip-to-frame bolt
2 - Park brake cable union
3 2853 Front park brake cable
1. Remove the parking brake control. For additional information, refer to Parking Brake Control in this
section.
100-02 .
3. Remove the front park brake cable P-clip-to-frame bolt.

4. Remove the front parking brake and conduit.

Pry the rubber seal from the front floor pan.
Compress the retainer and release the conduit from the bracket.
Remove the front cable and conduit from the cable union.
Parking Brake Cable - Front 2245

Parking Brake Cable - Front 2246

Parking Brake Cable - Rear, RH

1 2853 Front parking brake cable
2 2A635 RH parking brake cable
3 2A602 Parking brake cable equalizer
4 2A809 LH parking brake cable
5 - Wire form bracket (part of 2A635)
6 W506423 Wire form bracket bolt
7 2A709 Parking brake cable retaining spring
8 W506423 Rear parking brake cable-to-crossmember bolt
9 W506423 Wire form bracket bolt
10 2A637 RH parking brake shoe lever
1. Relieve the tension on the parking brake cable system. For additional information, refer to Parking
Brake Cable Tension Release in this section.
Section 100-02 .
3. Disconnect the RH rear cable from the cable union.
4. Compress the 2 tabs and release the conduit from the equalizer.
5. Disconnect the RH rear cable from the retaining clip.
6. Remove the bolt and the wire form bracket from the LH side of the vehicle.
Parking Brake Cable - Rear, RH 2247

7. Remove the rear parking brake cable-to-crossmember bolt.

8. Remove the bolt and the wire form bracket from the RH side of the vehicle.
9. Release the parking brake cable from the RH bracket assembly.
10. Release the cable from the parking brake actuating lever and remove the cable.
Parking Brake Cable - Rear, RH 2248

Parking Brake Cable - Rear, LH

1 2A602 Parking brake cable equalizer
2 2A809 LH rear parking brake cable
3 2A709 Parking brake cable retainer spring
4 2A637 Parking brake shoe lever
100-02 .
3. Separate the LH rear cable from the equalizer.
Compress the 2 tabs and remove the conduit from the bracket.
5. NOTE: Be sure to correctly install the park brake cable retainer spring and route cables between
suspension links.
Parking Brake Cable - Rear, LH 2249

Disconnect the parking brake cable retainer spring from the cable.
6. Disconnect the LH rear cable from the retaining clip.
7. Disconnect the ABS wheel speed sensor wire from the retaining clip.
8. Release the parking brake cable from the LH bracket assembly.
9. Release the cable from the parking brake actuating lever and remove the cable.
Parking Brake Cable - Rear, LH 2250

Parking Brake Shoes
Material
Item Specification
Dielectric Compound
XG-3-A

1 - Parking brake shoe adjuster spring (part of 2648)
2 2041 Parking brake shoe adjuster
3 - Parking brake shoe retaining clip (2 required)
(part of 2648)
4 - Parking brake shoe return spring (part of 2648)
5 2A753 Parking brake shoe (part of 2648)
6 - Parking brake shoe retaining pin (2 required) (part
of 2648)
7 2404 Parking brake shoe lever boot
(Navigator/Expedition)
8 2092 Adjuster hole plug
9 2C029 LH/ 2C028 Brake disc shield
RH
Removal
2. Remove the brake disc. For additional information, refer to Section 206-04 .
3. Remove the front parking brake shoe retaining clip and pin.
4. Remove the parking brake shoe adjuster.
Parking Brake Shoes 2251

Using a suitable tool, spreottom of the parking brake shoes apart.
Remove the parking brake shoe adjuster.
5. Remove the parking brake shoe adjuster spring.
6. Slide the front parking brake shoe up and out of the guide flange.
7. Remove the front parking brake shoe.

Rotate the front parking brake shoe outward.
Remove the parking brake shoe return spring.
8. Remove the rear parking brake shoe.

Remove the retaining clip and pin.
Remove the rear parking brake shoe.
9. Inspect the components for excessive wear or damage and install new parts as required.
Installation
1. NOTICE: Apply the grease only where indicated, do not apply the grease to the parking brake
shoes. The grease will contaminate the brake shoe linings and damage to the linings will result.
Apply a light coat of the specified grease to the 6 parking brake shoe contact points on the disc brake
shield.
2. Install the rear parking brake shoe.

Hold the rear parking brake shoe in position.
Install the retaining pin and clip.
3. Install the front parking brake shoe.

Install the parking brake shoe return spring to the rear parking brake shoe and to the front
parking brake shoe.
Rotate the front parking brake shoe into the guide flange.
4. Slide the front parking brake shoe down into position on the flange.
5. Install the front parking brake shoe retaining pin and clip.
6. Install the parking brake shoe adjuster spring.
7. Install the parking brake shoe adjuster.

Using a suitable tool, spread the bottom of the parking brake shoes apart.
Install the parking brake shoe adjuster.
8. Adjust the parking brake shoes. For additional information, refer to Parking Brake Shoe Adjustment
in this section.

9. NOTE: This step will require the aid of an assistant.
Enable the parking brake cable system.
Pull down on the front parking brake cable at the coupler.

Remove the retaining pin from the parking brake lever.
10. Check the parking brake for correct operation.

SECTION 206-06: Hydraulic Brake Actuation 2011 Expedition, Navigator Workshop Manual
Material

Capacity
(Canada)

Brake master cylinder nuts 25 18 -
Brake pedal bracket nuts and bolts 27 20 -
Brake tube fittings 25 18 -
Coolant expansion tank assembly bolts 15 - 133

Hydraulic Brake Actuation
Hydraulic Brakes
The hydraulic brake actuation system consists of the following components:
Brake master cylinder and fluid reservoir

Brake tubes and hoses
Brake pedal and bracket
The brake pedal is connected to the power brake booster, which is connected to the brake master cylinder.
When the brake pedal is pressed, brake fluid is forced through the double-walled steel tubes and flexible hoses
to the HCU . The brake fluid is then distributed to the front and rear brake calipers. The fluid enters the
caliper, forcing the caliper pistons and brake pads outward against the brake disc friction surface, slowing or
stopping rotation of the brake disc. When the brake pedal is released, brake fluid pressure is relieved,
returning the front and rear brake caliper pistons and brake pads to the unapplied position.
For information on the HCU , refer to Section 206-09 .
Adjustable Pedals
Adjustable brake and accelerator pedals are available as an optional feature on this vehicle. The brake pedal
position can be changed in phase with the accelerator pedal to increase driver comfort. Two different
adjustable pedal systems are available; one that is connected to the memory feature option and one that is not
connected to the memory feature option.
Without Memory Feature
Adjustable brake pedals without memory feature consist of the following components:
Adjustable brake pedal and bracket

Adjustable accelerator pedal and bracket, refer to Section 310-02
Adjustable pedal motor
Adjustable pedal cables
The pedals are adjusted through the use of a rocker switch mounted on the instrument panel. When the switch
is pressed, voltage is sent to the motor which spins a cable that is attached to the adjustable brake pedal. As
the cable spins, the pedals move either forward (away from the driver) or rearward (toward the driver)
depending on how the switch is pressed.
With Memory Feature
Adjustable brake and accelerator pedals are available as an optional feature on this vehicle. The brake pedal
position can be changed in phase with the accelerator pedal to increase driver comfort. Two different
adjustable pedal systems are available; one that is connected to the memory feature option and one that is not
Hydraulic Brake Actuation 2255

connected to the memory feature option.
Adjustable brake pedals with memory feature consist of the following components:
Driver Seat Module (DSM), refer to Section 501-10

Memory SET switch, refer to Section 501-10
Remote Keyless Entry (RKE) transmitter, refer to Section 501-14
Adjustable brake pedal and bracket
Adjustable accelerator pedal and bracket, refer to Section 310-02
Adjustable pedal cables
The pedals are adjusted through the use of a rocker switch mounted on the instrument panel, the memory SET
switch mounted on the seat trim panel or the door trim panel or the RKE transmitter. When the switch is
pressed or the transmitter is activated, a voltage signal is sent to the DSM . The DSM then sends voltage to the
adjustable pedal motor which spins a cable that is attached to the adjustable brake pedal. As the cable spins,
the pedals move either forward (away from the driver) or rearward (toward the driver) depending on how the
switch is pressed and/or current pedal position.
Hydraulic Brake Actuation 2256

Hydraulic Brakes
To diagnose hydraulic brake concerns, refer to Section 206-00 .
Adjustable Pedals
The brake and accelerator pedals can be adjusted closer to or further away from the driver to achieve a more
comfortable driving position.
The adjustable pedals can be adjusted in 1 of 3 ways:
By pressing the adjustable pedal switch

By pressing a memory position switch
By using the Remote Keyless Entry (RKE) transmitter
The adjustable pedals can be adjusted using the adjustable pedal switch at any time. The memory position 1
switch, memory position 2 switch or the RKE transmitter can only be used to recall a memory position when
the transmission selector lever is in the PARK position. The adjustable pedals are controlled by the Driver
Seat Module (DSM). The DSM receives input from 1 of the 3 sources and then powers the adjustable pedal
motor in the desired direction. The DSM will also control the driver seat position and the side-view mirror
positions.
For information on the DSM and Memory Position Programming, refer to Section 501-10 .

Inspection And Verification
Special Tool(s)

1. Verify the customer concern by operating the adjustable pedals.
Adjustable Adjustable pedal switch

pedal cable Driver Seat Module (DSM)
Adjustable Memory position 1 switch
pedal motor Memory position 2 switch
Adjustable Remote Keyless Entry (RKE) transmitter
pedals Battery Junction Box (BJB) fuse 74 (30A)
Foreign Smart Junction Box (SJB) fuse(s): - 2 (15A) - 20
material (15A)

<


If the scan tool responds with no communication for one or more modules, refer to
Section 418-00 .
If the network test passes, retrieve and record Continuous Memory Diagnostic
Trouble Codes (CMDTCs).
8. Clear the continuous DTCs and carry out the self-test diagnostics for the Driver Seat Module
(DSM).
9. If the DTCs retrieved are related to the concern, go to Driver Seat Module (DSM) DTC Chart.
For all other DTCs, refer to Section 419-10 .
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart - Adjustable Pedals
Without Memory Feature or GO to Symptom Chart - Adjustable Pedals With Memory
Feature .

Diagnostic Trouble Code (DTC) Charts

B1987 Pedal Forward/Rearward Motor Stalled GO to Pinpoint Test D .
B1988 Pedal Position Forward Switch Circuit Short to Battery GO to Pinpoint Test B .
B1989 Pedal Position Rearward Switch Circuit Short to Battery GO to Pinpoint Test B .
B1991 Pedal Forward/Rearward Potentiometer Feedback Circuit Short to GO to Pinpoint Test D .
Battery
B2275 Pedal Forward/Rearward Potentiometer Feedback Circuit Short to GO to Pinpoint Test D .
Ground
- All Other DSM DTCs REFER to Section 501-10 .
Diagnostic Trouble Code (DTC) Charts 2260

Symptom Charts
Symptom Chart - Adjustable Pedals Without Memory Feature
Symptom Chart - Adjustable Pedals Without Memory Feature
Symptom Chart - Adjustable Pedals With Memory Feature
Symptom Chart - Adjustable Pedals With Memory Feature
Symptom Charts 2261

Pinpoint Tests
Special Tool(s)
Flex Probe Kit


Test Light SGT2700 or equivalent 250-350

mA incandescent bulb test lamp
SGT2700
Pinpoint Test A: Adjustable Brake Pedal is Inoperative/Does Not Operate Correctly (Without Memory
Feature)
Refer to Wiring Diagrams Cell 127 , Adjustable Pedals for schematic and connector information.
Normal Operation
The adjustable pedal switch receives fused battery voltage from Smart Junction Box (SJB) fuse 20 (15A)
along circuit SBP20 (GN/RD).
When the adjustable pedal switch is pressed in the forward position (away from the driver), the switch
connects circuit SBP20 (GN/RD) with circuit CPP01 (WH/OG) and the voltage is sent to the adjustable pedal
motor along circuit CPP01 (WH/OG). The current returns to the switch along circuit CPP02 (BN) and is
grounded through the switch along circuit GD138 (BK/WH).
When the adjustable pedal switch is pressed in the rearward position (toward the driver), the switch connects
circuit SBP20 (GN/RD) with circuit CPP02 (BN) and the voltage is sent to the adjustable pedal motor along
circuit CPP02 (BN). The current returns to the switch along circuit CPP01 (WH/OG) and is grounded through
the switch along circuit GD138 (BK/WH).

Fuse
Foreign material
Adjustable pedal cable
Adjustable brake pedal assembly
Adjustable accelerator pedal assembly
Pinpoint Tests 2262

PINPOINT TEST A: ADJUSTABLE BRAKE PEDAL IS INOPERATIVE/DOES NOT OPERATE CORRECTLY (WITHOUT
MEMORY FEATURE)

A1 CHECK THE ADJUSTABLE PEDAL
MOTOR AND CABLE INSTALLATION
Yes
Check the adjustable pedal motor and cable for GO to A2 .
Are the motor and cable correctly installed? No
CORRECT the adjustable pedal motor
installation. TEST the system for normal
operation.
A2 INSPECT FOR FOREIGN MATERIAL
Yes
Inspect the adjustable brake pedal and GO to A3 .
accelerator assemblies for foreign material
causing a binding condition. No
Are the pedal assemblies free from foreign REMOVE the foreign material. TEST the
material? system for normal operation.
A3 TEST THE ADJUSTABLE PEDAL SWITCH
Yes
Disconnect: Adjustable Pedal Switch C2089.
Carry out the adjustable pedal switch No
component test. INSTALL a new adjustable pedal switch. TEST
component testing.
Does the adjustable pedal switch pass the
component test?
A4 CHECK FOR VOLTAGE AT THE
ADJUSTABLE PEDAL SWITCH
Yes
Measure the voltage between adjustable pedal GO to A5 .
switch C2089-2, circuit SBP20 (GN/RD),
VERIFY SJB fuse 20 (15A) is OK. If OK,
REPAIR circuit SBP20 (GN/RD). If not OK,
REFER to the Wiring Diagrams manual to
identify the cause for the circuit short. TEST the


SWITCH GROUND CIRCUIT FOR AN OPEN
Yes
Measure the resistance between ground and: GO to A6 .
adjustable pedal switch C2089-4,
circuit GD138 (BK/WH), harness side. No
adjustable pedal switch C2089-6, REPAIR circuit GD138 (BK/WH). TEST the
circuit GD138 (BK/WH), harness side. system for normal operation.

MOTOR CIRCUITS FOR AN OPEN
Yes
Disconnect: Adjustable Pedal Motor C2159. GO to A7 .
Measure the resistance between adjustable
pedal switch C2089, harness side and No
adjustable pedal motor C2159, harness side as REPAIR the affected circuit(s). TEST the
indicated in the following chart: system for normal operation.
Adjustable Adjustable
Pedal Switch Circuit Pedal Motor
C2089-1 CPP02 (BN) C2159-1
C2089-5 CPP01 C2159-2
(WH/OG)

MOTOR CIRCUITS FOR A SHORT TO GROUND
PINPOINT TEST A: ADJUSTABLE BRAKE PEDAL IS INOPERATIVE/DOES NOT OPERATE CORRECTLY

2264
Measure the resistance between ground and: Yes

adjustable pedal switch C2089-1, GO to A8 .
circuit CPP02 (BN), harness side.
adjustable pedal switch C2089-5, No
circuit CPP01 (WH/OG), harness side. REPAIR the affected circuit(s). TEST the

ohms?
MOTOR CIRCUITS FOR A SHORT TO
VOLTAGE
Yes
Ignition ON. REPAIR the affected circuit(s). TEST the
Measure the voltage between ground and: system for normal operation.
adjustable pedal switch C2089-1,
circuit CPP02 (BN), harness side. No
adjustable pedal switch C2089-5, GO to A9 .
circuit CPP01 (WH/OG), harness side.

A9 CHECK THE ADJUSTABLE BRAKE PEDAL
CABLE OPERATION
Yes
Connect: Adjustable Pedal Motor C2159. INSTALL a new brake pedal assembly. REFER
Connect: Adjustable Pedal Switch C2089. to Brake Pedal and Bracket in this section.
Disconnect the adjustable brake pedal cable TEST the system for normal operation.
from the adjustable brake pedal.
Operate the adjustable pedal control switch and No
observe the cable in the conduit. GO to A10 .
Does the adjustable brake pedal cable turn
in the conduit?
A10 ISOLATE THE ADJUSTABLE
ACCELERATOR PEDAL ASSEMBLY
Yes
Disconnect the adjustable brake pedal cable INSTALL a new brake pedal motor cable.
from the adjustable pedal motor. TEST the system for normal operation.
Operate the adjustable pedal control switch and
observe the accelerator pedal. No
PINPOINT TEST A: ADJUSTABLE BRAKE PEDAL IS INOPERATIVE/DOES NOT OPERATE CORRECTLY

2265
Does the adjustable accelerator pedal move REPAIR the adjustable accelerator pedal
according to switch position? system. REFER to Section 310-02 . TEST the
Pinpoint Test B: Adjustable Brake Pedal is Inoperative/Does Not Operate Correctly - Using the
Adjustable Pedal Switch (With Memory Feature)
Normal Operation
The adjustable pedal switch receives fused battery voltage from Smart Junction Box (SJB) fuse 20 (15A)
along circuit SBP20 (GN/RD).
When the adjustable pedal switch is pressed in the forward position (away from the driver), the switch
connects circuit SBP20 (GN/RD) with circuit CPP09 (VT/OG) and the voltage is sent to the Driver Seat
Module (DSM) along circuit CPP09 (VT/OG). The DSM then sends voltage to the adjustable pedal motor
along circuit CPP01 (WH/OG), and the current returns to the DSM along circuit CPP02 (BN).
When the adjustable pedal switch is pressed in the rearward position (toward the driver), the switch connects
circuit SBP20 (GN/RD) with circuit CPP10 (BN/BU) and the voltage is sent to the DSM along circuit CPP10
(BN/BU). The DSM then sends voltage to thedjustable pedal motor along circuit CPP02 (BN), and the current
returns to the DSM along circuit CPP01 (WH/OG).
DTC B1988 (Pedal Position Forward Switch Circuit Short to Battery) - If during normal operation or
an on-demand self test, the DSM detects battery voltage on circuit CPP09 (VT/OG) for more than 2
minutes, DTC B1988 will be set.
DTC B1989 (Pedal Position Rearward Switch Circuit Short to Battery) - If during normal operation or
an on-demand self test, the DSM detects battery voltage on circuit CPP10 (BN/BU) for more than 2
minutes, DTC B1989 will be set.

Foreign material
Fuse
Adjustable pedal cable
Brake pedal assembly
DSM
PINPOINT TEST B: ADJUSTABLE BRAKE PEDAL IS INOPERATIVE/DOES NOT OPERATE CORRECTLY - USING
THE ADJUSTABLE PEDAL SWITCH (WITH MEMORY FEATURE)

B1 CHECK THE DSM DTCs
Yes
GO to B8 .

Review the DTCs retrieved during Inspection and

Verification. No
Are DTCs B1988 and/or B1989 present? GO to B2 .
B2 CHECK THE DSM ADJUSTABLE PEDAL SWITCH
(PEDPOSSW) PID
Yes
Connect the scan tool. GO to B9 .
Ignition ON.
DataLogger - DSM . GO to B3 .
Monitor the PEDPOSSW PID while activating the
adjustable pedal switch.
Does the PID display match the switch position within
one second of pressing the switch?
B3 ISOLATE THE ADJUSTABLE PEDAL SWITCH
Yes
Carry out the adjustable pedal switch component test.
No
Refer to Wiring Diagrams Cell 149 for component testing. INSTALL a new adjustable pedal
Does the adjustable pedal switch pass the component switch. CLEAR the DTCs.
test? REPEAT the self-test.
B4 CHECK FOR VOLTAGE AT THE ADJUSTABLE
PEDAL SWITCH
Yes
Disconnect: Adjustable Pedal Switch C2089 .
Measure the voltage between adjustable pedal switch No
C2089-2, circuit SBP20 (GN/RD), harness side and ground. VERIFY SJB fuse 20 (15A) is OK.
If OK, REPAIR circuit SBP20
(GN/RD). If not OK, REFER to
the Wiring Diagrams manual to
identify the possible cause for the
circuit short. TEST the system for
normal operation.

B5 CHECK THE ADJUSTABLE PEDAL SWITCH
CIRCUITS FOR A SHORT TOGETHER
Yes
Disconnect: DSM C341C. GO to B6 .
Measure the resistance between adjustable pedal switch
C2089-5, circuit CPP09 (VT/OG), harness side and No
C2089-1, circuit CPP10 (BN/BU), harness side. REPAIR the affected circuit(s).
self-test.
PINPOINT TEST B: ADJUSTABLE BRAKE PEDAL IS INOPERATIVE/DOES NOT OPERATE CORRECTLY

2267

Yes
Measure the resistance between ground and: GO to B7 .
adjustable pedal switch C2089-1, circuit CPP10
(BN/BU), harness side. No
adjustable pedal switch C2089-5, circuit CPP09 REPAIR the affected circuit(s).
(VT/OG), harness side. CLEAR the DTCs. REPEAT the
self-test.

Yes
Measure the resistance between adjustable pedal switch GO to B8 .
C2089, harness side and DSM C341C, harness side as
indicated in the following chart: No
REPAIR the affected circuit(s).
self-test.
Adjustable Pedal Switch Circuit DSM

C2089-1 CPP10 (BN/BU) C341C-9
C2089-5 CPP09 (VT/OG) C341C-21


2268
Disconnect: DSM C341C (if not previously disconnected). Yes

Disconnect: Adjustable Pedal Switch C2089 (if not REPAIR the affected circuit(s) for
previously disconnected). a short to voltage. CLEAR the
Measure the voltage between ground and:
adjustable pedal switch C2089-1, circuit CPP10 No
(BN/BU), harness side. If DTCs B1988 and/or B1989 are
adjustable pedal switch C2089-5, circuit CPP09 not present, GO to B9 .
(VT/OG), harness side.
If DTCs B1988 and/or B1989 are
present, GO to B18 .

B9 CHECK THE DSM ADJUSTABLE PEDAL ACTIVE
COMMANDS
Yes
Connect: DSM C341C. The system is operating correctly
Select PARK. at this time. The concern may have
Ignition ON. been caused by a loose or corroded
Enter the following diagnostic mode on the scan tool: connector. CLEAR the DTCs.
DataLogger - DSM . REPEAT the self-test.
NOTE: Toggling the active command ON will cause the
pedal to move in the commanded direction for 2 seconds and No
then the pedal will stop. GO to B10 .
Toggle the pedal forward (PEDAL_FWD) active command
ON.
Toggle the PEDAL_FWD active command OFF.
Toggle the pedal rearward (PEDAL_RWD) active command
ON.
Toggle the PEDAL_FWD active command OFF.
Do the adjustable pedals respond correctly to the
corresponding active commands?
B10 CHECK THE ADJUSTABLE PEDAL MOTOR AND
CABLE INSTALLATION
Yes
GO to B11 .
No
Check the adjustable pedal motor and cable for correct CORRECT the adjustable pedal
installation. motor installation. TEST the
Are the motor and cable correctly installed? system for normal operation.
B11 INSPECT FOR FOREIGN MATERIAL
Yes
Inspect the adjustable brake pedal and accelerator GO to B12 .
assemblies for foreign material causing a binding condition.
Are the pedal assemblies free from foreign material? No
REMOVE the foreign material.

2269

operation.
B12 CHECK THE ADJUSTABLE PEDAL MOTOR
Yes
Disconnect: Adjustable Pedal Motor C2159.
Disconnect: DSM C341C. No
Measure the resistance between DSM C341C, harness side REPAIR the affected circuit(s).
and adjustable pedal motor C2159, harness side as indicated CLEAR the DTCs. REPEAT the
in the following chart: self-test.
DSM Circuit Adjustable Pedal Motor

C341C-12 CPP01 (WH/OG) C2159-2
C341C-24 CPP02 (BN) C2159-1

Yes
Measure the resistance between ground and: GO to B14 .
DSM C341C-12, circuit CPP01 (WH/OG), harness
side. No
DSM C341C-24, circuit CPP02 (BN), harness side. REPAIR the affected circuit(s).
self-test.


2270
Ignition ON. Yes

Measure the voltage between ground and: REPAIR the affected circuit(s).
DSM C341C-12, circuit CPP01 (WH/OG), harness CLEAR the DTCs. REPEAT the
side. self-test.
DSM C341C-24, circuit CPP02 (BN), harness side.
No
GO to B15 .

B15 CHECK FOR DSM OUTPUT
Yes
NOTICE: The following step uses a test light to simulate GO to B16 .
normal circuit loads. Use only the test light
recommended in the Special Tools table at the beginning No
of this section. To avoid connector terminal damage, use GO to B18 .
the Flex Probe Kit for the test light probe connection to
the vehicle. Do not use the test light probe directly on
any connector.
Connect: DSM C341C.

Connect: Adjustable Pedal Switch C2089.
Connect the positive lead of a test light to C2159-1, circuit
CPP02 (BN), harness side.
Connect the negative lead of a test light to C2159-2, circuit
CPP01 (WH/OG), harness side.
Press the adjustable pedal switch in the forward position and

verify that the test light is illuminated.
Press the adjustable pedal switch in the rearward position
and verify that the test light is illuminated.
Does the test light illuminate when the adjustable pedal
switch is pressed in each direction?
B16 INSPECT THE ADJUSTABLE BRAKE PEDAL CABLE
Yes
Disconnect the adjustable brake pedal cable from the GO to B17 .
adjustable brake pedal.
Inspect the ends of the brake pedal motor cable for wear or No
damage. INSTALL a new adjustable
Are the cable ends OK? accelerator pedal assembly.

2271

self-test. TEST the system for
normal operation.
B17 CHECK THE ADJUSTABLE BRAKE PEDAL CABLE
OPERATION
Yes
Connect: Adjustable Pedal Switch C2089. INSTALL a new brake pedal
Connect: Adjustable Pedal Motor C2159. assembly. REFER to Brake Pedal
Connect: DSM C341C. and Bracket in this section. TEST
Disconnect the adjustable brake pedal cable from the the system for normal operation.
adjustable brake pedal.
Operate the adjustable pedal control switch and observe the No
cable in the conduit. INSTALL a new adjustable
Does the adjustable brake pedal cable turn in the accelerator pedal assembly.
conduit? REFER to Section 310-02 .
self-test. TEST the system for
normal operation.
B18 CHECK THE DSM FOR CORRECT OPERATION
Yes
Disconnect: DSM C341C (if not previously disconnected). INSTALL a new DSM . REFER to
Check DSM C341C for: Section 501-10 . CLEAR the
corrosion. DTCs. REPEAT the self-test.
pushed-out pins.
Connect: DSM C341C. The system is operating correctly
Make sure the connector seats correctly, then operate the at this time. The concern may have
system and verify the concern is still present. been caused by a loose or corroded
Is the concern still present? connector. CLEAR the DTCs.
Pinpoint Test C: Adjustable Brake Pedal is Inoperative/Does Not Operate Correctly - Using the
Memory SET Switch Buttons or the Remote Keyless Entry (RKE) Transmitter
Normal Operation
When the desired memory position is selected using the memory SET switch buttons or the remote
transmitter, the Driver Seat Module (DSM) will send voltage to the adjustable pedal motor along circuit
CPP01 (WH/OG) to move the pedals forward and along circuit CPP02 (BN) to move the pedals rearward.
When voltage is sent to the motor along circuit CPP01 (WH/OG) it returns to the DSM along circuit CPP02
(BN). Likewise, when the voltage is sent to the motor along circuit CPP02 (BN), it returns to the DSM along
circuit CPP01 (WH/OG).
The DSM uses a Hall-effect switch attached to the pedal motor to identify the current pedal position. The
DSM sends a reference voltage along circuit LPP06 (YE/BU), through the Hall-effect switch and back to the
DSM along the signal return circuit, RPP06 (GN).


DSM
PINPOINT TEST C: ADJUSTABLE BRAKE PEDAL IS INOPERATIVE/DOES NOT OPERATE CORRECTLY - USING
THE MEMORY SET SWITCH BUTTONS OR THE RKE TRANSMITTER

C1 CHECK THE ADJUSTABLE PEDAL OPERATION WITH
THE ADJUSTABLE PEDAL SWITCH
Yes
Press the adjustable pedal switch in each direction for more GO to C2 .
than one second and observe the adjustable pedals.
Do the adjustable pedals operate for more than one second No
in the direction selected using the switch? If the pedals do not move at all
using the switch, GO to
Pinpoint Test B .
If the pedals only move in one

second intervals regardless of
button operation, GO to
Pinpoint Test D .
C2 CHECK THE MEMORY SYSTEM OPERATION
Yes
Set a memory position for the driver seat, exterior mirrors and GO to C3 .
adjustable pedals to memory SET switch button 1. Refer to
Memory Position Programming in Section 501-10 . No
Select PARK. If all 3 items do not move,
Press the memory SET switch button 1 and observe the REFER to Diagnosis and
following items: Testing in Section 501-10 to
Driver seat DIAGNOSE the memory SET
Exterior mirrors switch.
Adjustable pedals
Do all 3 items move when the button is pressed? If only the adjustable pedals do
not move, GO to C4 .
If only the driver seat does not

move, REFER to Diagnosis and
Testing in Section 501-10 .
If only the exterior mirrors do

not move, REFER to Diagnosis
and Testing in Section 501-09 .
C3 CHECK THE RKE TRANSMITTER OPERATION
Yes
Set a memory position in the RKE transmitter for the driver GO to C4 .
seat, exterior mirrors and adjustable pedals. Refer to Remote
Memory Activation in Section 501-14 . No
Select PARK. If all 3 items do not move,
PINPOINT TEST C: ADJUSTABLE BRAKE PEDAL IS INOPERATIVE/DOES NOT OPERATE CORRECTLY

2273
Press the unlock button on the RKE transmitter and observe the REFER to Diagnosis and
following items: Testing in Section 501-14 to
Driver seat DIAGNOSE the RKE
Exterior mirrors transmitter.
Adjustable pedals
Do all 3 items move when the button is pressed? If only the adjustable pedals do
not move, GO to C4 .
If only the driver seat does not

move, REFER to Diagnosis and
Testing in Section 501-10 .
If only the exterior mirrors do

not move, REFER to Diagnosis
and Testing in Section 501-09 .
C4 CHECK THE ADJUSTABLE PEDAL MOTOR AND CABLE
INSTALLATION
Yes
Check the adjustable pedal motor and cable for correct GO to C5 .
installation.
Are the motor and cable correctly installed? No
CORRECT the adjustable pedal
motor installation. TEST the
C5 INSPECT FOR FOREIGN MATERIAL
Yes
Inspect the adjustable brake pedal and accelerator assemblies GO to C6 .
for foreign material causing a binding condition.
Are the pedal assemblies free from foreign material? No
REMOVE the foreign material.
operation.
C6 CHECK THE DSM PEDAL MOTOR AND HALL-EFFECT
Yes
Disconnect: Adjustable Pedal Motor C2159. GO to C7 .
Disconnect: DSM C341C.
Measure the resistance between DSM C341C, harness side and No
adjustable pedal motor C2159, harness side as indicated in the REPAIR the affected circuit(s).
following chart: TEST the system for normal
operation.
DSM Circuit Adjustable Pedal Motor

C341C-12 CPP01 (WH/OG) C2159-2
C341C-24 CPP02 (BN) C2159-1
C341C-15 RPP06 (GN) C2159-6
C341C-3 LPP06 (YE/BU) C2159-4

2274

Yes
Measure the resistance between ground and: GO to C8 .
DSM C341C-3, circuit LPP06 (YE/BU), harness side.
DSM C341C-12, circuit CPP01 (WH/OG), harness No
side. REPAIR the affected circuit(s).
DSM C341C-15, circuit RPP06 (GN), harness side. TEST the system for normal
DSM C341C-24, circuit CPP02 (BN), harness side. operation.

Yes
Measure the resistance between DSM C341C pins, harness side GO to C9 .
as indicated in the following chart:
No
operation.
DSM Circuit DSM Circuit
C341C-3 LPP06 (YE/BU) C341C-12 CPP01 (WH/OG)
C341C-3 LPP06 (YE/BU) C341C-15 RPP06 (GN)
C341C-3 LPP06 (YE/BU) C341C-24 CPP02 (BN)
C341C-12 CPP01 (WH/OG) C341C-15 RPP06 (GN)
C341C-12 CPP01 (WH/OG) C341C-24 CPP02 (BN)
C341C-15 RPP06 (GN) C341C-24 CPP02 (BN)

2275

Yes
Ignition ON. REPAIR the affected circuit(s).
Measure the voltage between ground and: TEST the system for normal
DSM C341C-3, circuit LPP06 (YE/BU), harness side. operation.
DSM C341C-12, circuit CPP01 (WH/OG), harness
side. No
DSM C341C-15, circuit RPP06 (GN), harness side. INSTALL a new adjustable
DSM C341C-24, circuit CPP02 (BN), harness side. accelerator pedal assembly.
the self-test. TEST the system
Pinpoint Test D: DTC B1987, B1991 or B2275
Normal Operation
The Driver Seat Module (DSM) uses a Hall-effect switch attached to the pedal motor to identify the current
pedal position. The DSM sends a reference voltage along circuit LPP06 (YE/BU), through the Hall-effect
switch and back to the DSM along the signal return circuit RPP06 (GN).
When 1 or more of the following DTCs are set, the adjustable pedals will enter a "jog mode". When the pedals
are in jog mode, the memory system recall will not function from either the Remote Keyless Entry (RKE)
transmitter or the memory SET switch buttons. When the pedals are actuated using the adjustable pedal
switch, the motor will move the pedals for one second in the direction selected regardless of the length of time
the button is actually pressed.
DTC B1987 (Pedal Forward/Rearward Motor Stalled) - This DTC is only set during a DSM
on-demand self test. During the self test, the adjustable pedal motor will be commanded to move
forward and then rearward. If the motor encounters a hard stop while moving, the DSM will attempt
to move the pedals in the opposite direction. If the DSM does not see any pedal movement via the
Hall-effect switch during this attempt, DTC B1987 will be set and the adjustable pedal system will be
disabled.
DTC B1991 (Pedal Forward/Rearward Potentiomer Feedback Circuit Short to Battery) - If the DSM
detects a short to voltage on circuit LPP06 (YE/BU) during normal operation or an on-demand self
test and without any pedal switch input, DTC B1991 will be set.
DTC B2275 (Pedal Forward/Rearward Potentiometer Feedback Circuit Short to Ground) - If the DSM
detects a short to ground on circuit LPP06 (YE/BU) during normal operation or an on-demand self
test and without any pedal switch input, DTC B2275 will be set.


PINPOINT TEST D: DTC B1987, B1991 OR B2275

D1 CHECK THE DSM HALL-EFFECT
Yes
Disconnect: Adjustable Pedal Motor C2159.
Disconnect: DSM C341C. No
Measure the resistance between DSM C341C, REPAIR the affected circuit(s). CLEAR the
harness side and adjustable pedal motor DTCs. REPEAT the self-test.
C2159, harness side as indicated in the
following chart:
Adjustable Pedal
DSM Circuit Motor
C341C-15 RPP06 (GN) C2159-3
C341C-3 LPP06 C2159-4
(YE/BU)

Yes
Measure the resistance between ground and: GO to D3 .
DSM C341C-3, circuit LPP06
(YE/BU), harness side. No
DSM C341C-15, circuit RPP06 (GN), REPAIR the affected circuit(s). CLEAR the
harness side. DTCs. REPEAT the self-test.
PINPOINT TEST D: DTC B1987, B1991 OR B2275 2277


ohms?
Yes
Measure the resistance between DSM GO to E4 .
C341C-15, circuit RPP06 (GN), harness side
and DSM C341C-3, circuit LPP06 (YE/BU), No
harness side. REPAIR the affected circuit(s). CLEAR the

Yes
Ignition ON. REPAIR the affected circuit(s). CLEAR the
Measure the voltage between ground and: DTCs. REPEAT the self-test.
DSM C341C-3, circuit LPP06
(YE/BU), harness side. No
DSM C341C-15, circuit RPP06 (GN), If DTC B1987 was retrieved, GO to Pinpoint
harness side. Test B .
For all other DTCs, INSTALL a new adjustable

accelerator pedal assembly. REFER to Section
310-02 . CLEAR the DTCs. REPEAT the
self-test. TEST the system for normal operation.


Brake Master Cylinder
Material
Item Specification
(Canada)

1 2C156 Brake master cylinder and reservoir
assembly
2 W520212 Brake master cylinder nut (2 required)
3 - Primary brake tube fitting (part of 2A040)
4 - Secondary brake tube fitting (part of
2B253)
5 - Brake fluid level switch electrical
connector (part of 12A581)
6 2152 Brake master cylinder-to-brake booster seal
7 - Vacuum sensor wiring harness locator (part
of 9C490)
8 - Front axle vent hose locator (part of
3B476)
Brake Master Cylinder 2280


NOTICE: Do not spill brake fluid on painted surfaces or damage to the surface may occur. If brake
fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.
1. Disconnect the brake fluid level switch.
2. Remove the air cleaner element. For additional information, refer to Section 303-12 Intake Air
Distribution and Filtering.
3. Remove the 2 bolts and position the coolant expansion tank assembly aside.
To install, tighten bolts to 15 Nm (133 lb-in).
4. Loosen the brake tube fittings and disconnect the brake tubes.
Plug the master cylinder ports.
To install, tighten the fittings to 25 Nm (18 lb-ft).
5. If equipped, detach the vacuum sensor wiring harness locator and front axle vent hose locator from
the master cylinder mounting studs.
6. NOTICE: When the master cylinder is removed, the piston will be exposed. Do not damage the
piston or piston surface or a fluid leak may occur.
Remove the 2 brake master cylinder nuts and the brake master cylinder.

Bleed the master cylinder. For additional information, refer to Section 206-00 .


Brake Pedal and Bracket
NOTE: Adjustable brake pedal and bracket shown, fixed brake pedal and bracket similar.

1 W702368 Brake pedal bracket bolts
2 - Accelerator pedal-to-brake pedal cable (part of 9F836)
3 2450 Brake pedal and bracket
4 W520212 Brake pedal bracket nut (4 required)
5 2L523 Brake pedal pin
Adjustable pedal vehicles
1. NOTICE: The brake pedal and the accelerator pedal must be in the same position when
installing a new cable or a new pedal. The pedals must be all the way forward or all the way
rearward or damage to components may occur.
Disconnect the accelerator pedal-to-brake pedal cable from the adjustable brake pedal gear set.
All vehicles
2. NOTICE: Do not service the brake pedal or brake booster without first removing the stoplamp
switch. This switch must be removed with the brake pedal in the at-rest position. The switch
plunger must be compressed for the switch to rotate in the bracket. Attempting to remove the
switch when the plunger is extended (during pedal apply) will result in damage to the switch.
Remove the stoplamp switch. For additional information, refer to Section 417-01 .
Brake Pedal and Bracket 2283

3. NOTE: An 11 mm, 12-point socket or wrench can be used to compress the 2 tabs on the brake pedal
arm pin.
Remove and discard the brake pedal pin, then disconnect the brake booster push rod from the brake
pedal arm.
4. Remove the bulkhead sound insulator.
5. Remove t 4 brake pedal bracket nuts.

6. Remove the 2 brake pedal bracket bolts and remove the brake pedal and bracket.
7. NOTICE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp
switch. This switch must be installed with the booster push rod attached to the brake pedal and
with the brake pedal in the at-rest position. Installing this switch with the brake pedal in any
other position will result in incorrect adjustment and may damage the switch.

SECTION 206-07: Power Brake Actuation 2011 Expedition, Navigator Workshop Manual

Brake booster nut a - - -
Brake master cylinder nut 25 18 -
Coolant expansion tank assembly bolts 15 - 133

Brake Booster
The power brake actuation system consists of the following components:
Brake booster
Brake booster check valve
Brake booster vacuum supply hose
The brake booster uses engine vacuum from the intake manifold to create a partial vacuum inside the vacuum
booster on both sides of the diaphragm. When the brake pedal is pressed, the booster rod opens a valve,
allowing air to enter the booster on one side of the diaphragm while sealing off the opposite side. This
increases pressure on that side of the diaphragm so that it helps push the rod, which in turn pushes the piston
in the master cylinder. As the brake pedal is released, the valve seals off the outside air supply while opening
the vacuum valve. This restores vacuum to both sides of the diaphragm, allowing everything to return to its
original position.
Brake Booster 2286

Power Brake System
Power Brake System 2287

Brake Booster

1 2L523 Brake pedal pin
2 W520212 Brake booster-to-pedal bracket nut (4 required)
3 2005 Brake booster
4 2365A Vacuum sensor assembly
5 W520212 Brake master cylinder nut (2 required)
6 2140 Brake master cylinder assembly
7 2152 Brake master cylinder-to-booster seal
8 - Gasket (part of 2B022)
9 - Spacer
10 - Gasket (part of 2B022)
1. Remove the Air Cleaner (ACL) element. For additional information, refer to Section 303-12 .
2. Remove the 2 bolts and position the coolant expansion tank assembly aside.
To install, tighten bolts to 15 Nm (133 lb-in).
Brake Booster 2288

3. Relieve the vacuum in the brake booster by pressing and releasing the brake pedal a minimum of 5
times with the engine not running.
4. Disconnect the brake fluid level switch.
5. Remove the 2 brake master cylinder nuts and position the master cylinder aside.
Support the master cylinder with mechanic's wire.
To install, tighten the nuts to 25 Nm (18 lb-ft).
6. NOTE: To allow proper drainage of any moisture, the vacuum sensor must be installed in the same
position and orientation as removed.
Detach the vacuum sensor assembly from the brake booster.
7. NOTICE: service the brake pedal or brake booster without first removing the stoplamp switch.
This switch must be removed with the brake pedal in the at-rest position. The switch plunger
must be compressed for the switch to rotate in the bracket. Attempting to remove the switch
when the plunger is extended (during pedal apply) will result in damage to the switch.
Remove the stoplamp switch. For additional information, refer to Section 417-01 .
8. NOTE: The booster push rod clevis-locking pin is a one-time use only part. Any time the booster
push rod clevis-locking pin is removed, a new booster push rod clevis-locking pin should be used.
NOTE: Remove the clevis-locking pin by squeezing the locking tabs and pulling outward on the
opposite end.
Remove and discard the booster push rod clevis-locking pin.
9. Remove the 4 brake booster-to-pedal bracket nuts and remove the brake booster.
To access the nuts, fold back the sound insulation.
To install, tighten the nuts to 25 Nm (18 lb-ft) following a clockwise pattern starting with the
upper left nut.
10. NOTICE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp
switch. This switch must be installed with the booster push rod attached to the brake pedal and
with the brake pedal in the at-rest position. Installing this switch with the brake pedal in any
other position will result in incorrect adjustment and may damage the switch.
Brake Booster 2289

Brake Booster 2290

Brake Booster Vacuum Sensor

1 - Vacuum sensor electrical connector (part of 12A581)
2 - Vacuum supply hose (part of 9C490)
3 2365A Brake booster vacuum sensor
1. Relieve the vacuum in the brake booster by pressing and releasing the brake pedal a minimum of 5
times with the engine not running.
2. Detach the vacuum supply hose from the brake booster vacuum sensor.
3. Disconnect the vacuum sensor electrical connector and remove the vacuum sensor.
4. NOTE: To allow proper drainage of any moisture, the vacuum sensor must be installed in the same
position and orientation as removed.
Brake Booster Vacuum Sensor 2291


SECTION 206-09: Anti-Lock Brake System (ABS) and Stability 2011 Expedition, Navigator
Control Workshop Manual
SPECIFICATIONS
08/12/2010
Material

Capacity
High Performance DOT 3 WSS-M6C62-A or 1420 ml
(Canada)
CPM-4 (Canada)
XG-4 and/or XL-5

ABS module bolts 2 - 18
Air Cleaner (ACL) outlet clamp 4 - 35
Front floor console bracket lower bolts 40 30 -
Front floor console bracket upper bolts 9 - 80
Front wheel speed sensor harness bolt 12 - 106
Front wheel speed sensor bolt 18 - 159
Hydraulic Control Unit (HCU)-to-bracket bolts 9 - 80
HCU bracket-to-frame bolts 20 - 177
Master cylinder primary and secondary brake tube fittings 25 18 -
Rear combination valve brake tube fitting 20 - 177
Rear wheel speed sensor bolt 18 - 159
RH and LH front brake tube fitting 20 - 177
Steering wheel rotation sensor bolts 3 - 27


DESCRIPTION AND OPERATION
08/12/2010
Anti-Lock Control
ABS With AdvanceTrac
The ABS with AdvanceTrac consists of the following components:
ABS module - attached to the Hydraulic Control Unit (HCU), but can be serviced separately.
Brake booster vacuum sensor - located in the brake booster and can be serviced separately from the
booster. Refer to Section 206-07 .
Front wheel speed sensors - one sensor is located in each front wheel knuckle. The sensors are
serviced separately from the knuckle.
Front wheel speed sensor tone rings - one tone ring is located in each wheel bearing and wheel hub
assembly and is serviced with the wheel bearing and wheel hub. Refer to Section 204-01A or Section
204-01B .
HCU - contains several valves (inlet, outlet, isolation and dump) and the hydraulic pump motor. It is
mounted behind the battery and battery tray.
Rear wheel speed sensors - one sensor is located in each rear wheel knuckle, the sensors are serviced
separately from the knuckle.
Rear whnsor tone rings - one tone ring is located in each wheel bearing and wheel hub assembly and
is serviced with the wheel bearing and wheel hub. Refer to Section 204-02 .
Restraints Control Module (RCM) - located under the front floor console and contains several sensors
(yaw rate, roll rate, lateral and longitudinal accelerometers).
Steering wheel rotation sensor - located at the end of the steering column on the LH side of the
column, the slotted wheel is serviced with the steering column.
Stability/traction control switch - part of the power liftgate/traction control/hazard center stack switch
assembly located in the instrument panel finish panel. The switch assembly is serviced separately
from the finish panel.
Electronic Brake Distribution (EBD)
The ABS module and HCU incorporate a strategy called Electronic Brake Distribution (EBD). The EBD
strategy uses the HCU as an electronic proportioning valve to create a balanced braking condition between the
front and rear wheels and minimize the chance of rear wheel lockup during hard braking. A slight bump may
be felt in the brake pedal when EBD is active.
Standard ABS
The ABS aids in the prevention of wheel lock-up during braking events which allows the driver to maintain
steering control and stop in the shortest distance possible under most conditions. This is accomplished by the
ABS module and HCU modulating brake fluid pressure to the affected brake caliper(s).
When the anti-lock control system activates, any of the following can occur:
A rumble or grinding sound may be heard

If the driver's foot is on the brake pedal, a vibration may be felt in the brake pedal
Anti-Lock Control 2295

AdvanceTrac System
Traction Control System
The traction control system aids in the prevention of excessive wheel spin which allows the vehicle to
maintain traction during acceleration. This is accomplished by the ABS module and the HCU modulating
brake fluid pressure to the affected brake caliper(s) and by the PCM modulating engine torque.
When the traction control system activates, any of the following can occur:
A rumble or grinding sound may be heard much like ABS

A small deceleration or a reduction in the acceleration of the vehicle
The stability/traction control indicator (sliding car icon) flashes
If the driver's foot is on the brake pedal, a vibration may be felt in the brake pedal much like ABS
Electronic Stability Control (ESC) System
The Electronic Stability Control (ESC) system constantlymonitors the vehicle's direction of travel relative to
the driver's intended course, except when the vehicle is traveling in reverse, and aids in keeping the vehicle
traveling along that course. This is accomplished by the ABS module and the HCU modulating brake fluid
pressure to the affected brake caliper(s) and by the PCM modulating engine torque.
When the ESC system activates, any of the following can occur:

Roll Stability Control (RSC) System
The Roll Stability Control (RSC) system constantly monitors vehicle motion relative to the driver's intended
course, except when the vehicle is traveling in reverse, and aids in keeping the vehicle stable during sudden or
abrupt maneuvers. This is accomplished by the ABS module and the HCU modulating brake fluid pressure to
the affected brake caliper(s) and by the PCM modulating engine torque. The combination of reduced engine
torque and modulated brake fluid pressure aids in reducing the cornering forces and, therefore, the total roll
momentum acting on the vehicle.
When the RSC system avates, any of the following can occur:

Stability/Traction Control Switch
The stability/traction control switch can be used by the driver to disable and enable the traction control, ESC
and RSC systems. When the ignition key is turned to the RUN position, all 3 systems are enabled and the
sliding-car icon in the Instrument Cluster (IC) illuminates momentarily as a test. When the switch is pressed,
the systems are disabled. When the systems are disabled, the sliding-car icon in the IC (or message center if
equipped) illuminates. The standard ABS cannot be disabled through the use of the stability/traction control
switch.
Traction Control System 2296

The AdvanceTrac system cannot be disabled when a MyKeyTM-restricted key is in use that has the
AdvanceTrac always-on feature configured "on". For information about MyKeyTM, refer to Section
419-01B
Roll Stability Control (RSC) System 2297

DIAGNOSIS AND TESTING
07/18/2011
Anti-Lock Control
Special Tool(s)
Flex Probe Kit


Rotunda Active Wheel Speed Sensor Tester

105-R0110

Anti-Lock Control
The anti-lock control system is controlled by the ABS module which continuously monitors and compares the
rotational speed of each wheel. The wheel speed sensors are connected to the ABS module by 2 circuits. One
circuit provides voltage for sensor operation and the other circuit provides sensor input to the ABS module.
As the wheels spin, the wheel speed sensor tone rings pass through the magnetic field generated by the active
wheel speed sensor. This causes the strength of the magnetic field to increase (as a tooth passes the sensor) or
decrease (as a gap passes the sensor) and generates a square-wave signal that is sent to the ABS module to
indicate individual wheel speed.
When the ABS module detects an impending wheel lock-up, brake fluid pressure to the appropriate brake
caliper is modulated (pulsated). This is accomplished by opening and closing the appropriate solenoid valves
inside the Hydraulic Control Unit (HCU) while the hydraulic pump motor is also actuated. Once the affected
wheel returns to normal speed, the ABS module returns the solenoid valves to their normal position and the
hydraulic pump motor is deactivated.
The ABS module is self-monitoring and carries out self-tests at pre-determined times. When the ignition
switch is turned to the RUN position, the ABS module carries out a preliminary electrical check of the wheel
speed sensors and their circuits by sending voltage through the sensor and checking for the voltage to return.
When the vehicle is traveling at speeds above 20 km/h (12 mph), and the brake pedal is not being pressed, the
pump motor is commanded ON for approximately 0.5 second to check pump motor operation. Also, during all
phases of operation while the vehicle is in motion, the ABS module checks for correct operation of the wheel
speed sensors by comparing wheel speed input to other sensor inputs. If a malfunction is detected, the ABS
module deactivates the ABS and also sends a message over the High Speed Controller Area Network
(HS-CAN). When the Instrument Cluster (IC) receives this message, it illuminates the yellow ABS warning

indicator and (if equipped) the stability/traction control indicator (sliding-car icon).
Electronic Brake Distribution (EBD)
On initial application of the brake pedal, full pressure is applied to the rear brakes. The ABS module then uses
wheel speed input to calculate an estimated rate of deceleration. Once vehicle deceleration exceeds a
predetermined threshold, the ABS module closes the appropriate isolation valves in the HCU to hold the rear
brake pressure constant while allowing the front brake pressure to build. This creates a balanced braking
condition between the front and rear wheels and minimizes the chance of rear wheel lockup during hard
braking. As the vehicle decelerates, the valves are opened to increase the rear brake pressure in proportion to
the front brake pressure.
If ABS is disabled due to DTCs being present in the ABS module, Electronic Brake Distribution (EBD)
continues to function unless the DTCs are for wheel speed sensors or the HCU . When EBD is disabled, the
red brake warning indicator, the ABS warning indicator and (if equipped) the sliding-car icon illuminates.
Optimized Hydraulic Braking
The ABS module incorporates a strategy called optimized hydraulic braking. This strategy uses the pump
motor in the HCU to provide brake pedal boost in the event that the vacuum brake booster fails. The brake
booster is equipped with a vacuum sensor. When vacuum in the booster falls below a predetermined level, a
DTC is set in the ABS module. If the brake pedal is applied with low vacuum in the booster, the ABS module
activates the pump motor in the HCU to assist with braking. During pump motor operation, the driver may
feel a pulsation in the brake pedal, accompanied by a slight up and down movement in the pedal height. In
addition, a mechanical noise may be heard.
Refer to Section 206-07 for sensor removal and installation information.
Traction Control System
The traction control system is controlled by the ABS module and uses the same wheel speed sensors and tone
rings that are used for the ABS. The ABS module continuously monitors and compares the rotational speed of
each wheel and when it detects a wheel spinning excessively, modulates brake pressure to the appropriate
brake caliper. This is accomplished by opening and closing the appropriate solenoid valves inside the HCU
while the hydraulic pump motor is activated. At the same time, the ABS module sends a message over the
HS-CAN that a traction control event is taking place. When the PCM receives this message, it assists with
traction control by adjusting engine timing and decreasing fuel injector pulses. When the IC receives this
message, it flashes the stability/traction control indicator (sliding-car icon). Once the affected wheel returns to
normal speed, the ABS module returns the solenoid valves in the HCU to their normal position, deactivates
the hydraulic pump motor and sends another message over the HS-CAN indicating that the traction event has
ended. The PCM returns engine timing and fuel injectors to normal operation and the IC extinguishes the
stability/traction control indicator.
Once vehicle speed reaches or exceeds 100 km/h (62 mph), traction control is accomplished only through the
PCM.
If the anti-lock control system is disabled due to DTCs being present in the ABS module, the traction control
system is disabled. When the traction control system is disabled due to DTCs being present, both the ABS
warning indicator and the stability/traction control indicator are illuminated.

Electronic Stability Control (ESC) System
The Electronic Stability Control (ESC) system is controlled by the ABS module and uses the same wheel
speed sensors and tone rings that are used for the anti-lock control system. The ESC system also uses input
from the steering wheel rotation sensor, the stability control sensors (yaw rate, longitudinal and lateral
acceleration located in the Restraints Control Module (RCM)) and information from other modules sent over
the HS-CAN to help maintain vehicle stability. The ABS module uses all of these inputs to continuously
monitor the vehicle's direction of travel relative to the driver's intended course. If the ABS module determines
from all these inputs that the vehicle is unable to travel in the intended direction, it modulates brake pressure
to the appropriate brake caliper(s) by opening and closing the appropriate solenoid valves inside the HCU
while the hydraulic pump motor is activated. At the same time, the ABS module sends a message over the
HS-CAN that a stability event is taking place. When the PCM receives this message, it assists with vehicle
stability by adjusting engine timing and decreasing fuel injector pulses. When the IC receives this message, it
flashes the stability/traction control indicator (sliding-car icon). Once the stability condition has been
corrected, the ABS module returns the solenoid valves in the HCU to their normal position, deactivates the
hydraulic pump motor and sends another message over the HS-CAN indicating that the event has ended. The
PCM returns engine timing and fuel injectors to normal operation and the IC extinguishes the stability/traction
control indicator.
If the anti-lock control system is disabled due to DTCs being present in the ABS module, the ESC system is
disabled. When the ESC system is disabled due to DTCs being present, both the ABS warning indicator and
the sliding-car icon are illuminated.
Roll Stability Control (RSC) System
The Roll Stability Control (RSC) system is controlled by the ABS module and uses the same wheel speed
sensors and tone rings that are used for the anti-lock control system. The RSC system also uses input from
the steering wheel rotation sensor, the stability control sensors (yaw rate, roll rate, longitudinal and lateral
acceleration) and information from other modules sent over the HS-CAN to help maintain vehicle stability.
The ABS module uses all of these inputs to continuously monitor vehicle motion relative to the driver's
intended course. If the ABS module determines from all these inputs that conditions exist for a potential
roll-over event, iodulates brake pressure to the appropriate brake caliper(s) by opening and closing the
appropriate solenoid valves inside the HCU while the hydraulic pump motor is activated. At the same time,
the ABS module sends a message over the HS-CAN that a stability event is taking place. When the PCM
receives this message, it assists with vehicle stability by adjusting engine timing and decreasing fuel injector
pulses. When the IC receives this message, it flashes the sliding-car icon. Once the stability condition has
been corrected, the ABS module returns the solenoid valves in the HCU to their normal position, deactivates
the hydraulic pump motor and sends another message over the HS-CAN indicating that the event has ended.
The PCM returns engine timing and fuel injectors to normal operation and the IC extinguishes the sliding-car
icon.
If the anti-lock control system is disabled due to DTCs being present in the ABS module, the RSC systems
are also disabled. When the RSC system is disabled due to DTCs being present, both the ABS warning
indicator and the sliding-car icon are illuminated.
Trailer Sway Control System
Trailer sway control is a unique function of the RSC system that uses information from the steering wheel
rotation sensor and the yaw information from the RCM to determine if a trailer sway event is taking place.
Trailer sway is the undesirable yaw force a trailer can apply to the towing vehicle. If the ABS module
determines that a trailer sway event is taking place, the module modulates brake pressure to the appropriate
brake caliper(s) by opening and closing the appropriate solenoid valves inside the HCU while the hydraulic

pump motor is activated. At the same time, the ABS module sends a message over the HS-CAN that a trailer
sway event is taking place. When the IC receives this message, it flashes the sliding-car icon and displays
TRAILER SWAY, REDUCE SPEED in the message center. If the event is severe enough, the ABS module
also sends a message to the PCM over the HS-CAN to assist with vehicle stability. When the PCM receives
this message, it adjusts engine timing and decreases fuel injector pulses. Once the trailer sway has been
corrected, the ABS module returns the solenoid valves in the HCU to their normal position, deactivates the
hydraulic pump motor and sends another message over the HS-CAN indicating that the event has ended. The
PCM returns engine timing and fuel injectors to normal operation and the IC extinguishes the sliding-car icon.
Trailer sway control only activates with vehicle speed greater than 64 km/h (40 mph). Any malfunction that
disables the RSC system also disables trailer sway control. Trailer sway control can also be disabled by
entering the setup menu in the message center. Refer to the Owner's Literature for the disabling/enabling
procedure. Regardless of the chosen state (enabled or disabled), trailer sway control is re-enabled at each
ignition key cycle.
Stability/Traction Control Switch
The stability/traction control switch provides the driver with the ability to disable only the traction control
feature. Standard ABS, ESC and RSC remain functional. The switch is hardwired to the ABS module. When
the stability/traction control switch is pressed, a ground signal is sent to the ABS module. The ABS module
then sends a message over the HS-CAN to the IC indicating that the driver has requested that the system be
deactivated and the IC illuminates the stability/traction control indicator (sliding-car icon). The ABS module
and the PCM ignores any traction events until the driver presses the switch again, the ignition key is cycled or
the vehicle speed reaches or exceeds 70 km/h (43 mph). Once the vehicle speed reaches or exceeds 70 km/h
(43 mph), the traction control system reactivates but the indicator remains illuminated.
The ESC system cannot be disabled when a MyKey-restricted key is in use that has the AdvanceTrac
always-on feature configured "on". If an attempt is made to disable the ESC system while a
MyKey-restricted key is in use, ADVTRAC ON MY KEY SETTING displays in the IC message center. For
information about MyKey, refer to Section 419-01B .
Stability/Traction Control Indicator "Sliding-Car Icon"
Status of the traction control, ESC and RSC systems is indicated by a stability/traction control indicator
(sliding-car icon) located in the IC (or message center if equipped). When the driver disables the systems
through the use of the stability/traction control switch, this indicator illuminates continuously, when one or
more of the systems is currently active, the indicator flashes and when the system is disabled due to DTCs
being present in the ABS module, the indicator illuminates in conjunction with the yellow ABS warning
indicator.
Stability Control Sensors
The stability control sensors for the ESC system include the yaw rate sensor, lateral and longitudinal
accelerometers. The yaw rate sensor, the lateral and longitudinal accelerometers are able to detect and
measure changes in vehicle direction that indicate the need for the A to make corrections that help prevent
vehicle roll over or spin outs. The sensors are housed in the Restraints Control Module (RCM) which sends
sensor information to the ABS module over the Controller Area Network (CAN). Install a new RCM if any of
the sensors are damaged.
Steering Wheel Rotation Sensor
Stability/Traction Control Indicator "Sliding-Car Icon" 2301

The steering wheel rotation sensor measures the rate of rotation of the steering wheel by monitoring the
slotted ring as it passes through the sensor gap. The rotation sensor uses 2 signal lines to transmit information
to the ABS module about whether the steering wheel is being turned left or right and how far it is being
turned. The rotation sensor does not indicate the position of the steering wheel relative to straight-ahead. The
AdvanceTrac system learns this position by comparing the steering wheel position with other signals and
storing the position it has learned. The AdvanceTrac system confirms this position and modifies it as
necessary during every new driving cycle.
Stability/Traction Control System Sensor Calibration
When a new RCM is installed, the sensor(s) must be calibrated. The calibration procedure is required for the
sensor(s) to learn the "zero-position" of the vehicle which means the vehicle must be on a level surface and
must not be moving.
If a DTC is logged for any component of the AdvanceTrac system, the DTC must be cleared or repaired
before carrying out the calibration procedure. The need to calibrate is also indicated by the stability/traction
control indicator flashing once every 2 seconds.
To carry out the calibion procedure, connect the scan tool, proceed to the IVD Initialization sequence and
follow the scan tool instructions.
ABS Module Configuration
The ABS module must be configured when a new module is installed. Refer to Programmable Module
Installation (PMI) in Section 418-01 .
2. Verify the stoplamps operate correctly by applying and releasing the brake pedal with the ignition in
the OFF position. If the stoplamps do not operate correctly, refer to Section 417-01 . If the stoplamps
operate correctly, proceed to the next step.
Base brake system ABS module

Brake booster vacuum Battery Junction Box (BJB)
hose fuse(s):
Hydraulic Control Unit 52 (10A)
(HCU) 68 (60A)
Steering components 69 (60A)
Suspension Brake Pedal Position (BPP)
components switch
Tire pressure

Tire size or Brake booster vacuum

mismatched tires sensor
Wheel speed sensor Stability/traction control
ring switch
Wheel speed sensor
Wiring, terminals or
connectors



418-00 .
(CMDTCs).
9. Clear the continuous DTCs and carry out the self-test diagnostics for the ABS module.
10. If the DTCs retrieved are related to the concern, go to the ABS Module DTC Chart. For all other
DTCs, refer to Section 419-10 .
DTC Charts
ABS Module DTC Chart

B1342 NOTE: An intermittent NOTE: If other DTCs are present, REPAIR them before installing a new
loss of power or ground component.
can cause this DTC to
set. INSPECT ABS module C135 for corrosion, pushed-out pins and spread
terminals. REPAIR as necessary. VERIFY that C135 is seated correctly.

ECU is Faulted INSPECT the eyelet and stud of ground G104. REPAIR as necessary.
CLEAR the DTCs. CARRY OUT the ABS module self-test. If DTC
B1342 is retrieved, INSTALL a new ABS module. REFER to Anti-Lock
Brake System (ABS) Module in this section. REPEAT the self-test.
B1483 Brake Pedal Input GO to Pinpoint Test A .
Circuit Failure
B1676 Battery Pack Voltage GO to Pinpoint Test B .
Out of Range
B2477 Module Configuration CONFIGURE the ABS module. REFER to Programmable Module
Failure Installation (PMI) in Section 418-01 . CLEAR the DTCs. REPEAT the
self-test. If DTC B2477 is retrieved again, INSTALL a new ABS module.
REFER to Anti-Lock Brake System (ABS) Module in this section.
B2900 VIN Mismatch GO to Pinpoint Test E .
C1095 ABS Hydraulic Pump GO to Pinpoint Test C .
Motor Circuit Failure
C109D Low Vacuum Condition GO to Pinpoint Test H .
C109E Vacuum Sensor Circuit GO to Pinpoint Test H .
Fault
C109F Vacuum Sensor Signal GO to Pinpoint Test H .
Fault
C1145 Wheel Speed Sensor RF GO to Pinpoint Test D .
Input Circuit Failure
C1155 Wheel Speed Sensor LF GO to Pinpoint Test D .
C1165 Wheel Speed Sensor RR GO to Pinpoint Test D .
C1175 Wheel Speed Sensor LR GO to Pinpoint Test D .
C1233 Wheel Speed LF Input GO to Pinpoint Test P .
Signal Missing
C1234 Wheel Speed RF Input GO to Pinpoint Test P .
Signal Missing
C1235 Wheel Speed RR Input GO to Pinpoint Test P .
Signal Missing
C1236 Wheel Speed LR Input GO to Pinpoint Test P .
Signal Missing
C1277 Steering Wheel Angle 1 GO to Pinpoint Test F .
and 2 Circuit Failure
C1278 Steering Wheel Angle 1 GO to Pinpoint Test F .
and 2 Signal Faulted
C1280 Yaw Rate Sensor Signal GO to Pinpoint Test N .
Fault
C1282 Lateral Accelerometer GO to Pinpoint Test N .
Signal Fault
C1288 Pressure Sensor GO to Pinpoint Test R .
Main/Primary Input
Circuit Failure
C1440

Pressure Sensor CLEAR the DTCs. REPEAT the self-test. If DTC C1440 is present,
Main/Primary Signal MAKE SURE all HCU and ABS module fasteners are tightened to their
Faulted correct torque specification. If all fasteners are tightened to their correct
torque specification, INSTALL a new HCU . REFER to Hydraulic Control
Unit (HCU) in this section.
C1470 TCS Function Disabled ALLOW the brake fluid time to cool. CLEAR the DTC. TEST DRIVE the
(brake fluid temperature vehicle and VERIFY ABS operation.
is above a pre-set limit)
C1516 Roll Rate Sensor Signal GO to Pinpoint Test N .
Fault
C1805 Mismatched PCM and/or CHECK for correct PCM and ABS module configuration using the scan
ABS-TC Module tool. CONFIGURE the component as necessary. REFER to Programmable
Module Installation (PMI) in Section 418-01 . CLEAR the DTC. REPEAT
the self-test.
C1963 Stability Assist Inhibit NOTE: This DTC does not clear until the vehicle has been driven above
Warning 48 km/h (30 mph) with input from the steering wheel rotation sensor.
GO to Pinpoint Test F .
C1991 Module Calibration CARRY OUT the IVD Initialization sequence. FOLLOW the scan tool
Failure directions. CLEAR the DTCs. REPEAT the self-test. If DTC C1991 is
retrieved again, INSTALL a new ABS module. REFER to Anti-Lock
Brake System (ABS) Module in this section.
C1996 Active Yaw and/or Roll GO to Pinpoint Test I .
Control Disabled
C2770 Longitudinal GO to Pinpoint Test N .
Acceleration Sensor
Plausibility Failure
U0001 High Speed CAN Bus REFER to Section 418-00 , to diagnose the High Speed Controller Area
Network (HS-CAN).
U0100 Lost Communication GO to Pinpoint Test J .
With ECM/PCM
U0101 Lost Communication GO to Pinpoint Test K .
With TCM
U0114 Lost Communication GO to Pinpoint Test L .
With Four-Wheel Drive
Clutch Control Module
U0140 Lost Communication GO to Pinpoint Test M .
With Body Control
Module
U0151 Lost Communication GO to Pinpoint Test N .
with Restraints Control
Module
U0155 Lost Communication GO to Pinpoint Test O .
With Instrument Cluster
U0401 Invalid Data Received If other DTCs are present along with U0401, REPAIR those DTCs first. If
From ECM /PCM U0401 is the only DTC present, CARRY OUT the PCM self-test.
RETRIEVE and RECORD any DTCs. REFER to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual to diagnose the PCM.
From Transmission U0402 is the only DTC present, CARRY OUT the transmission control

Control Module module self-test. RETRIEVE and RECORD any DTCs. REFER to the
Powertrain Control/Emissions Diagnosis (PC/ED) manual to diagnose the
Transmission Control Module (TCM).
From Four-Wheel Drive U0414 is the only DTC present, CARRY OUT the Four-Wheel Drive
Clutch Control Module (4WD) clutch control module self-test. RETRIEVE and RECORD any
DTCs. REFER to Section 308-07A to diagnose the 4WD clutch control
module.
U0452 Invalid Data Received GO to Pinpoint Test N .
from Restraints Control
Module
U1901 CAN Network #2 GO to Pinpoint Test N .
Communication Bus
Fault
U2050 No Application Present CONFIGURE the ABS module. REFER to Programmable Module
Installation (PMI) in Section 418-01 . CLEAR the DTCs. RETRIEVE the
DTCs and VERIFY successful module configuration. If DTC U2050 is
retrieved again, INSTALL a new ABS module. REFER to Anti-Lock
Brake System (ABS) Module in this section. CLEAR the DTC. REPEAT
the self-test.
U2051 One or More Calibration CLEAR the DTCs. CARRY OUT the ABS module self-test. If DTC
Files Missing or Corrupt U2051 is retrieved again, RECONFIGURE the ABS module using as-built
data. REFER to Programmable Module Installation (PMI), Using the
Integrated Diagnostic System (IDS) When the Original Module is NOT
Available in Section 418-01 . CLEAR the DTC and REPEAT the self-test.
If DTC U2051 returns, INSTALL a new ABS module. REFER to
Anti-Lock Brake System (ABS) Module in this section. CLEAR the DTC.
Symptom Chart
Symptom Chart
Pinpoint Tests
Pinpoint Test A: DTC B1483
Refer to Wiring Diagrams Cell 42 , Vehicle Dynamic Systems for schematic and connector information.
NOTE: The Brake Pedal Position (BPP) is also known as the stoplamp switch.
Normal Operation
When the brake pedal is pressed, the BPP switch opens and interrupts a voltage signal that is sent to the PCM.
When the PCM detects this interruption, it sends a message over the High Speed Controller Area Network
(HS-CAN) indicating that the brake pedahas been pressed. The PCM uses the BPP switch information for the
speed control system. The ABS module receives the BPP switch information from the PCM over the HS-CAN
.

DTC B1483 (Brake Pedal Input Open Circuit) - The ABS module compares the BPP message against
other inputs (brake pressure and wheel speed) and if the message does not match the other inputs and
there are no DTCs present for those inputs, DTC B1483 is set.

BPP switch
PCM
ABS module
PINPOINT TEST A: DTC B1483

A1 CHECK FOR PCM DTCs
Yes
Ignition ON. REFER to Section 419-10 .
on the scan tool: PCM KOEO No
Self-Test. GO to A2 CHECK THE ABS MODULE DTCs
Retrieve and record any PCM
DTCs.
Are any DTCs present in the
PCM?
Yes
Review the DTCs recorded during DIAGNOSE U0100 and/or U0401 before diagnosing
Inspection and Verification. DTC B1483. REFER to the ABS Module DTC Chart.
Are DTCs U0100 and/or U0401
also present? No
If DTC C1288 is present, GO to Pinpoint Test R .
If no other DTCs are present, GO to A3 .

A3 CHECK THE ABS MODULE
BRAKE ON/OFF (BOO_ABS) PID
Yes
Enter the following diagnostic mode The system is operating correctly at this time. CLEAR the
on the scan tool: ABS Module DTC. REPEAT the self-test.
DataLogger.
Monitor the BOO_ABS PID while No
pressing and releasing the brake GO to A4 .
pedal.
Does the PID agree with the pedal
position?
A4 CHECK THE PCM BOO1 PID
Yes
Enter the following diagnostic mode REFER to Section 418-00 to diagnose the communication
on the scan tool: DataLogger - PCM concern.
.
No
PINPOINT TEST A: DTC B1483 2307

Monitor the BOO1 PID while REFER to Section 419-03 and diagnose the speed control
pressing and releasing the brake deactivation switch.
pedal.
Does the PID agree with the pedal
position?
Pinpoint Test B: DTC B1676
Normal Operation
The operating voltage required to operate the ABS module, hydraulic pump and isolation valves is in a range
between 10 and 17 volts.
Fused battery voltage is supplied by the Battery Junction Box (BJB). Fused ignition voltage is also supplied
by the BJB .
DTC B1676 (Battery Pack Voltage Out of Range) - If the voltage to the ABS module is above 16
volts or below 10 volts, DTC B1676 is set.

Fuse(s)
Charging system/vehicle battery
ABS module
PINPOINT TEST B: DTC B1676
NOTE: DTC B1676 can be set if the vehicle has been recently jump started, the battery has been recently
charged or the battery has been discharged. The battery may become discharged due to excessive load(s) on
the charging system from aftermarket accessories or if the battery has been left unattended with the
accessories on.
NOTE: Carry out a thorough inspection and verification before proceeding with the pinpoint test. Refer to
Inspection and Verification in this section.

B1 RETRIEVE ALL CMDTCs IN ALL MODULES
Yes
Ignition ON. REFER to Section 414-00 for
Enter the following diagnostic mode on the scan tool: Self diagnosis of the battery and
Test - All Continuous Memory Diagnostic Trouble Codes charging system.
(CMDTCs) .
Is DTC B1317, B1318 or B1676 present in one or more No
modules AND DTC P0563, P0620, P0625, P0626 or GO to B2 .
P065B present in the PCM?
B2 CHECK BATTERY CONDITION

Ignition OFF. Yes

Carry out the Battery Condition Test. Refer to Section If the battery passed the condition
414-01 . test, but required a recharge,
Does the battery pass the condition test? REFER to Section 414-00 .
self-test.
If the battery passed the condition

test and did not require a recharge,
GO to B3 .
No
INSTALL a new battery. REFER
to Section 414-01 . CLEAR the
B3 CHECK CHARGING SYSTEM VOLTAGE
Yes
NOTE: Do not allow the engine speed to increase above GO to B4 .
2,000 rpm while carrying out this step or the generator may
self excite and result in default charging system output No
voltage. If engine speed goes above 2,000 rpm, shut the REFER to Section 414-00 to
vehicle OFF and restart the engine before carrying out this diagnose the charging system.
step. CLEAR all CMDTCs . TEST the
Supplemental Restraint System
Start the engine. (SRS) for normal operation.
Measure the voltage of the battery with and without a load
on the charging system as follows:
Turn off all accessories and run the engine at 1,500
rpm for a minimum of 2 minutes while measuring
battery voltage.
Turn on headlights and HVAC fan on high and run
engine at 1,500 rpm for a minimum of 2 minutes
while measuring battery voltage.
Are the voltages between 13 and 15.2 volts?

B4 CHECK THE VOLTAGE TO THE ABS MODULE
Yes
Disconnect: ABS Module C135.
Ignition ON. No
Measure the voltage between ground and: VERIFY BJB fuses 68 (60A), 69
ABS module C135-1, circuit SBB69 (GY/RD), (60A) and 52 (10A) are OK. If
harness side. OK, REPAIR the affected
ABS module C135-8, circuit CBB52 (GN/WH), circuit(s). If not OK, REFER to the
harness side. Wiring Diagrams manual to
identify the possible causes for the
PINPOINT TEST B: DTC B1676 2309

ABS module C135-32, circuit SBB68 (GN/RD), circuit short. CLEAR the DTC.
harness side. REPEAT the self-test.

B5 CHECK THE ABS MODULE GROUND CIRCUIT FOR
AN OPEN
Yes
Measure the resistance between ABS module C135-16,
circuit GD120 (BK/GN), harness side and ground. No
REPAIR circuit GD120 (BK/GN).
CLEAR the DTC. REPEAT the
self-test.

B6 CHECK FOR CORRECT ABS MODULE OPERATION
Yes
Check ABS module C135 for: INSTALL a new ABS module.
corrosion REFER to Anti-Lock Brake
pushed-out pins System (ABS) Module in this
spread terminals section. TEST the system for
Connect: ABS Module C135. normal operation.
Make sure the connector seats correctly, then operate the
system and verify the concern is still present. No
Is the concern still present? The system is operating correctly
at this time. The concern may have
been caused by a loose or corroded
connector. CLEAR the DTCs.
Pinpoint Test C: DTC C1095
Normal Operation
The operating voltage required to operate the hydraulic pump is in a range between 10 and 17 volts.
When the ignition key is turned to the ON position, the ABS module commands the Hydraulic Control Unit

(HCU) pump on for 100 ms (6 ms) and is then commanded off. After 6 ms, the ABS module reads the
voltage that is being generated by the HCU pump. If the voltage indicates the motor is spinning at less than
500 rpm, there may be a locked motor. If this condition is detected 4 times, DTC C1095 is set.
DTC C1095 (ABS Hydraulic Pump Motor Circuit Failure) - If during normal operation or the
on-demand self test, the ABS module detects an open circuit, a short circuit to voltage or ground, or if
there is an internal failure of the hydraulic pump motor or ABS module pump motor circuits, DTC
C1095 is set.

Fuse
HCU
ABS module
PINPOINT TEST C: DTC C1095

C1 CHECK THE ABS PUMP
MOTOR
Yes
Is the ABS pump motor
running all the time? No
GO to C2 .
C2 CHECK THE ABS MODULE
PUMP MOTOR (PMP_MOTOR)
ACTIVE COMMAND
Yes
Connect the scan tool. TOGGLE the PMP_MOTOR active command OFF. CLEAR
Ignition ON. the DTCs. CHECK the yellow ABS warning indicator while
Enter the following diagnostic driving the vehicle (brakes must not be applied) at greater than
mode on the scan tool: 40 km/h (25 mph). If the yellow ABS warning indicator
DataLogger - ABS Module . illuminates, RETRIEVE the DTCs. If DTC C1095 is
Toggle the PMP_MOTOR active retrieved, GO to C5 .
command ON.
Does the ABS pump motor run No
for approximately 2 seconds? TOGGLE the PMP_MOTOR output command OFF.O to C3 .
C3 CHECK THE PUMP MOTOR
VOLTAGE SUPPLY TO THE ABS
MODULE
Yes
Measure the voltage between No
ABS module C135-1, circuit VERIFY that BJB fuse 69 (60A) is OK. If OK, REPAIR
SBB69 (GY/RD), harness side circuit SBB69 (GY/RD). If not OK, REFER to the Wiring
and ground. Diagrams manual to identify the possible causes of the circuit
PINPOINT TEST C: DTC C1095 2311

short. CLEAR the DTCs. REPEAT the self-test.

volts?
C4 CHECK THE ABS MODULE
Yes
Measure the resistance between INSTALL a new HCU . REFER to Hydraulic Control Unit
ABS module C135-16, circuit (HCU) in this section. CLEAR the DTCs. REPEAT the
GD120 (BK/GN), harness side self-test.
and ground.
No
REPAIR circuit GD120 (BK/GN). CLEAR the DTCs.

ohms?
C5 CHECK FOR CORRECT ABS
MODULE OPERATION
Yes
Ignition OFF. INSTALL a new ABS module. REFER to Anti-Lock Brake
Disconnect: ABS Module C135. System (ABS) Module in this section. TEST the system for
Check the connector for: normal operation.
corrosion
pushed-out pins No
spread terminals The system is operating correctly at this time. The concern
Connect: ABS Module C135. may have been caused by a loose or corroded connector.
Make sure the connector seats CLEAR the DTCs. REPEAT the self-test.
correctly, then operate the
system and verify the concern is
still present.
Pinpoint Test D: DTCs C1145, C1155, C1165 and C1175
PINPOINT TEST C: DTC C1095 2312

Normal Operation
The active wheel speed sensor generates a signal that is sent to the ABS module. The wheel speed sensor
circuitry connects to the ABS module through 2 wires and a connector at each wheel speed sensor. When the
ignition switch is turned to the RUN position, the ABS module carries out a self-test by sending a reference
voltage through the right front wheel speed sensor and the related circuitry to determine if it is functional.
Voltage is supplied to the active wheel speed sensors from the ABS module, ground is also supplied by the
ABS module.

If during the ABS module on-demand self test or during normal operation, if the
C1145 - RF ABS module detects an open, short to ground or voltage or a damaged wheel speed
Wheel Speed sensor input circuit, the appropriate DTC is set. These DTCs are usually set by a
Sensor Input damaged sensor or a circuit fault.
Circuit Failure
C1155 - LF
Wheel Speed
Sensorut Circuit
Failure
C1165 - RR
Wheel Speed
Sensor Input
Circuit Failure
C1175 - LR
Wheel Speed
Sensor Input
Circuit Failure

Wheel speed sensor(s)
ABS module
PINPOINT TEST D: DTCs C1145, C1155, C1165 AND C1175
NOTICE: No measurements should be taken with the wheel speed sensor connected. Damage to the
wheel speed sensor results.
NOTE: Anytime a wheel speed sensor is removed, thoroughly clean the mounting surfaces and apply a thin
coating of grease.

D1 CHECK FOR FAULT REPEATABILITY

NOTE: Both circuits must be checked for Yes

each DTC. If the Rotunda Active Wheed Sensor Tester is
not available, GO to D4 .
Ignition ON. If the Rotunda Active Wheel Speed Sensor
Using the scan tool, clear all ABS module Tester is available, GO to D2 .
DTCs.
Drive the vehicle at least 16 km/h (10 mph). No
Enter the following diagnostic mode on the INSPECT the wheel speed sensors, wheel speed
scan tool: Self Test - ABS Module . sensor wiring and wheel speed sensor tone rings.
Retrieve and document all ABS module REPAIR or INSTALL new as necessary. If any
DTCs. other DTCs are retrieved, REFER to the ABS
Is DTC C1145, C1155, C1165 or C1175 Module DTC Chart.
retrieved?
D2 CHECK THE ABS MODULE OUTPUT
USING THE ROTUNDA ACTIVE WHEEL
SPEED SENSOR TESTER
Yes
Disconnect: Suspect Wheel Speed Sensor.
Connect the Rotunda Active Wheel Speed No
Sensor Tester to the wheel speed sensor GO to D6 .
connectors.
Select the correct system polarity on the
Rotunda Active Wheel Speed Sensor Tester
and turn the power switch to the ON position.
Ignition ON.
Is the module output LED illuminated?
D3 CHECK THE WHEEL SPEED SENSOR
OUTPUT WITH THE ROTUNDA ACTIVE
WHEEL SPEED SENSOR TESTER
Yes
Raise the suspect wheel until it can spin The system is operating correctly at this time.
freely. Refer to Section 100-02 . The concern may have been caused by a loose or
While monitoring the Rotunda Active Wheel corroded connector. CLEAR the DTCs.
Speed Sensor Tester, slowly spin the suspect REPEAT the self-test.
wheel.
Do the sensor output LEDs illuminate and No
flash and is the current overload LED not If the current level LED is not illuminated and
illuminated? the sensor output LEDs do not illuminate or if
the current level LED is illuminated red,
INSTALL a new wheel speed sensor. REFER to
Wheel Speed Sensor - Front or Wheel Speed
Sensor - Rear in this section. CLEAR the DTCs.
If the current level LED is not illuminated and

the sensor output LEDs illuminate green but do
not flash, INSPECT the wheel speed sensor tone
ring and INSTALL new if necessary. If the tone
ring is OK, INSTALL a new wheel speed sensor.
REFER to Wheel Speed Sensor - Front or Wheel
Speed Sensor - Rear in this section. CLEAR the
PINPOINT TEST D: DTCs C1145, C1155, C1165 AND C1175 2314


Yes
Disconnect: ABS Module C135. DTCs. REPEAT the self-test.
Ignition ON. No
For DTC C1145 , measure the voltage GO to D5 .
between:
ABS module C135-34, circuit VCA05
(GY/VT), harness side and ground.
ABS module C135-33, circuit RCA19
(VT), harness side and ground.
For DTC C1155 , measure the voltage

between:
(VT/WH), harness side and ground.
(YE), harness side and ground.

between:
(WH/OG), harness side and ground.

between:


(BU/OG), harness side and ground.
(BN/GN), harness side and ground.

Yes
For DTC C1145 , measure the resistance
between: No
ABS module C135-34, circuit VCA05 REPAIR the affected circuit(s). CLEAR the
(GY/VT), harness side and ground. DTCs. REPEAT the self-test.
(VT), harness side and ground.

between:
(YE), harness side and ground.

between:
(WH/OG), harness side and ground.


between:
(BU/OG), harness side and ground.

ohms?
Yes
NOTE: Both circuits must be checked for GO to D7 .
each DTC.
No
Disconnect: ABS Module C135. DTCs. REPEAT the self-test.
Measure the resistance between the ABS
module connector, harness side and the
suspect wheel speed sensor connector, harness
side as follows:
ABS Wheel Speed

Module Circuit Sensor
DTC C1145
C135-34 VCA05 C160-2
(GY/VT)
C135-33 RCA19 (VT) C160-1
DTC C1155
C135-45 VCA03 C150-2
(VT/WH)
C135-46 RCA17 (YE) C150-1

DTC C1165
C135-43 VCA06 C426-2
(WH/OG)
C135-42 RCA20 (BN) C426-1
DTC C1175
C135-36 VCA04 C440-2
(BU/OG)
C135-37 RCA18 C440-1
(BN/GN)

D7 CHECK FOR WHEEL SPEED SENSOR
CIRCUITS SHORTED TOGETHER
Yes
For DTC C1145 , measure the resistance GO to D8 .
between RF wheel speed sensor C160-2,
circuit VCA05 (GY/VT), harness side and RF No
wheel speed sensor C160-1, circuit RCA19 REPAIR the affected circuit(s). CLEAR the
(VT), harness side. DTCs. REPEAT the self-test.
between LF wheel speed sensor C150-2,
circuit VCA03 (VT/WH), harness side and LF
wheel speed sensor C150-1, circuit RCA17
(YE), harness side.
between RR wheel speed sensor C426-2,
circuit VCA06 (WH/OG), harness side and
RR wheel speed sensor C426-1, circuit
RCA20 (BN), harness side.
between LR wheel speed sensor C440-2,
circuit VCA04 (BU/OG), harness side and LR
(BN/GN), harness side.

ohms?
D8 CHECK THE ABS MODULE OUTPUT

NOTE: If the 2 wheel speed sensor circuits Yes

are shorted together, the ABS module shuts INSTALL a new wheel speed sensor. REFER to
down those circuits and no voltage is present Wheel Speed Sensor - Front or Wheel Speed
at the connectors. If this happens, cycle the Sensor - Rear in this section. CLEAR the DTC.
ignition key and take the measurement again, REPEAT the self-test.
being careful not to short the 2 wheel speed
sensor circuits together. No
GO to D9 .
Connect: ABS Module C135.
Ignition ON.
between RF wheel speed sensor C160-2,
circuit VCA05 (GY/VT), harness side and RF
(VT), harness side.
between LF wheel speed sensor C150-2,
circuit VCA03 (VT/WH), harness side and LF
(YE), harness side.
between RR wheel speed sensor C426-2,
circuit VCA06 (WH/OG), harness side and
RR wheel speed sensor C426-1, circuit
RCA20 (BN), harness side.
between LR wheel speed sensor C440-2,
circuit VCA04 (BU/OG), harness side LR
(BN/GN), harness side.

D9 CHECK FOR CORRECT ABS MODULE
OPERATION
Yes
Ignition OFF. INSTALL a new ABS module. REFER to
Disconnect: ABS Module C135. Anti-Lock Brake System (ABS) Module in this
Check ABS module C135 for: section. TEST the system for normal operation.
corrosion
pushed-out pins No
spread terminals The system is operatiorrectly at this time. The
Connect: ABS Module C135. concern may have been caused by a loose or
Make sure the connector seats correctly, then corroded connector. CLEAR the DTCs.
operate the system and verify the concern is REPEAT the self-test.
still present.

Pinpoint Test E: DTC B2900
Normal Operation
When the ignition is turned to the RUN position, the ABS module and the PCM share Vehicle Identification
Number (VIN) information over the High Speed Controller Area Network (HS-CAN).
DTC B2900 ( VIN Mismatched) - If the VIN information stored in the ABS module does not match
the information transmitted by the PCM, DTC B2900 sets.

Module configuration
ABS module
PINPOINT TEST E: DTC B2900

E1 VERIFY THE PCM VIN
Yes
Ignition ON.
Enter the following No
diagnostic mode on the scan RECONFIGURE the PCM. FOLLOW the instructions on the scan
tool: Log Viewer. tool. CLEAR the DTCs. CYCLE the ignition key. REPEAT the
Compare the VIN in Log self-test.
Viewer to the vehicle V
plate.
Does VIN in Log Viewer
match the vehicle VIN
plate?
E2 VERIFY THE ABS
MODULE PART NUMBER
Yes
Retrieve and record the CONFIGURE the ABS module. REFER to Section 418-01 ,
ABS module part number Programmable Module Installation (PMI) Using the Integrated
from Log Viewer and verify Diagnostic System (IDS) When the Original Module is NOT
that the vehicle has the Available. CLEAR the DTC. CYCLE the ignition key. REPEAT
correct ABS module the self test.
installed.
Is the correct ABS module No
installed in the vehicle? INSTALL a new ABS module. REFER to Anti-Lock Brake System
(ABS) Module in this section. CLEAR the DTC. CYCLE the
ignition key. REPEAT the self-test.
Pinpoint Test F: DTCs C1277, C1278 and C1963

Normal Operation
The steering wheel rotation sensor monitors the steering wheel position when the slotted-wheel on the steering
shaft passes through the infrared light generated by the sensor.
The steering wheel position (in degrees) is sent to the ABS module along a pair of signal circuits.
DTC C1277 (Steering Wheel Angle 1 and 2 Circuit Failure) - If during normal operation or the ABS
module on-demand self test, the ABS module detects an open circuit, short to voltage or short to
ground along circuits VCS06 (GY/BN) or VCS07 (VT/OG), DTC C1277 is set. An internal failure of
the steering wheel rotation sensor may also cause DTC C1277 to set.
DTC C1278 (Steering Wheel Angle 1 and 2 Signal Faulted) - If during normal operation or the ABS
module on-demand self test, the ABS module does not receive the steering wheel rotation sensor input
or if the input received does not agree with the input from other sensors, DTC C1278 is s
DTC C1963 (Stability Assist Inhibit Warning) - If conditions exist during normal operation that
prevents the roll stability control system from operating, DTC C1963 is set. This DTC is usually set
due to the steering wheel rotation sensor being damaged or installed incorrectly.

Steering wheel rotation sensor incorrectly installed
Steering wheel rotation sensor
ABS module
PINPOINT TEST F: DTCs C1277, C1278 AND C1963

F1 CHECK THE STEERING WHEEL ROTATION
SENSOR CONDITION AND INSTALLATION
Yes
Inspect the steering wheel rotation sensor and GO to F2 /a>.
slotted-wheel for damage and correct installation.
Refer to Steering Wheel Rotation Sensor in this No
section. REINSTALL or INSTALL new as
Are the sensor and slotted-wheel installed necessary. REFER to Steering Wheel
correctly and undamaged? Rotation Sensor in this section. CLEAR the
DTCs. CYCLE the ignition key. REPEAT
the self-test.
F2 MONITOR THE STEERING POSITION
SENSOR PID (SWA POS)
Yes
Center the steering wheel. CLEAR the DTCs. DRIVE the vehicle.
Connect the scan tool. RETRIEVE the DTCs.
Ignition ON.
Enter the following diagnostic mode on the scan If DTC C1277 or C1278 are present (with or
tool: ABS Module DataLogger. without other DTCs present), GO to F10 .
Monitor the SWA POS PID while rotating the
steering wheel clockwise and counterclockwise For all other DTCs, REFER to the ABS
very slowly, from lock to lock. Module DTC Chart.

Does the PID change in intervals of 4.5 degrees

and show a 360 degree increase for each No
complete revolution of the steering wheel? GO to F3 .
F3 CHECK THE VOLTAGE TO THE STEERING
WHEEL ROTATION SENSOR
Yes
Disconnect: Steering Wheel Rotation Sensor C226.
Ignition ON. No
Measure the voltage between steering wheel REPAIR circuit CCS01 (VT/WH). START
rotation sensor C226-4, circuit CCS01 (VT/WH), the engine. ROTATE the steering wheel
harness side and ground. from lock to lock a minimum of 2 times.
CLEAR the DTCs. REPEAT the self-test.

SENSOR GROUND CIRCUIT FOR AN OPEN
Yes
Measure the voltage between steering wheel GO to F5 .
rotation sensor C226-4, circuit CCS01 (VT/WH),
harness side and steering wheel rotation sensor No
C226-1, circuit RCS02 (BU/WH), harness side. REPAIR circuit RCS02 (BU/WH). START
the engine. ROTATE the steering wheel
from lock to lock a minimum of 2 times.

SENSOR SIGNAL 1 CIRCUIT FOR AN OPEN OR A
SHORT TO GROUND
Yes
rotation sensor C226-2, circuit VCS06 (GY/BN),
C226-1, circuit RCS02 (BU/WH), harness side. REPAIR circuit VCS06 (GY/BN). START
PINPOINT TEST F: DTCs C1277, C1278 AND C1963 2322

Is the voltage between 4.75 volts and 5.25 volts?

SENSOR SIGNAL 2 CIRCUIT FOR AN OPEN OR A
SHORT TO GROUND
Yes
rotation sensor C226-3, circuit VCS07 (VT/OG),
C226-1, circuit RCS02 (BU/WH), harness side. REPAIR circuit VCS07 (VT/OG). START
Is the voltage between 4.75 volts and 5.25 volts?

F7 CHECK THE STEERING POSITION SENSOR
Yes
Measure the resistance between the ABS module No
connector, harness side and the steering wheel REPAIR the affected circuit(s). CLEAR the
rotation sensor connector, harness side as follows: DTCs. START the engine. ROTATE the
steering wheel from lock to lock a minimum
of 2 times. REPEAT the self-test.
ABS Steering Wheel

Module Circuit Rotation Sensor
C135-9 VCS07 C226-3
(VT/OG)
C135-40 RCS02 C226-1
(BU/WH)
C135-41 VCS06 C226-2
(GY/BN)


Yes
Measure the voltage between: DTCs. START the engine. ROTATE the
ABS module C135-9, circuit VCS07 steering wheel from lock to lock a minimum
(VT/OG), harness side and ground. of 2 times. REPEAT the self-test.
ABS module C135-40, circuit RCS02
(BU/WH), harness side and ground. No
ABS module C135-41, circuit VCS06 GO to F9 .
ABS module C135-5, circuit CCS01

Yes
Ignition OFF. If DTC C1963 is not present, INSTALL a
Measure the resistance between: new steering wheel rotation sensor. REFER
ABS module C135-9, circuit VCS07 to Steering Wheel Rotation Sensor in this
(VT/OG), harness side and ground. section. CLEAR the DTCs. REPEAT the
ABS module C135-40, circuit RCS02 self-test.
(BU/WH), harness side and ground.
ABS module C135-41, circuit VCS06 No
(GY/BN), harness side and ground. REPAIR the affected circuit(s). CLEAR the
ABS module C135-5, circuit CCS01 DTCs. START the engine. ROTATE the
(VT/WH), harness side and ground. steering wheel from lock to lock a minimum
of 2 times. REPEAT the self-test.

F10 CHECK FOR CORRECT ABS MODULE

OPERATION
Yes
Disconnect: ABS Module C135. Anti-Lock Brake System (ABS) Module in
Check ABS module C135 for: this section. CLEAR the DTCs. REPEAT
corrosion the self-test.
pushed-out pins
spread terminals No
Connect: ABS Module C135. The system is operating correctly at this
Make sure the connector seats correctly, then time. The concern may have been caused by
operate the system and verify the concern is still a loose or corroded connector. CLEAR the
present. DTCs. REPEAT the self-test.
Pinpoint Test G: DTC U0001
Normal Operation
DTC U0001 (Lost Communication With Restraints Control Module: No Sub Type Information) - a
continuous memory DTC set by the ABS module if it does not receive yaw or other sensor messages
from the Restraints Control Module (RCM) for 5 seconds or longer.

Communication network concern
RCM
ABS module
PINPOINT TEST G: DTC U0001

G1 VERIFY THE CUSTOMER CONCERN
Yes
Verify that there is an observable symptom
present. No
Is an observable symptom present? The system is operating normally at this time. The
DTC may have been set due to high network traffic
or an intermittent fault condition.
G2 CHECK THE COMMUNICATION
NETWORK
Yes
Enter the following diagnostic mode on
the scan tool: Network Test. No
Carry out the network test. REFER to Section 418-00 .
Does the RCM pass the network test?
G3 RETRIEVE THE RECORDED DTCs
FROM THE ABS MODULE AND RCM
MODULE SELF-TESTS
PINPOINT TEST G: DTC U0001 2325

Check for recorded DTCs from the Yes

self-test. For the ABS module DTC B1676, GO to Pinpoint
Is DTC B1676 or DTCs B1317 or B1318 Test B .
recorded?
For the RCM DTCs B1317 or B1318, REFER to
Section 501-20B .
No
GO to G4 .
G4 RECHECK THE ABS MODULE DTCs
Yes
Clear the DTCs. GO to G5 .
Wait 10 seconds.
Repeat the ABS module self-test. No
Is DTC U0151 still present? The system is operating correctly at this time. The
G5 CHECK FOR DTCs U0151 OR U0151:00
SET IN OTHER MODULES
Yes
Clear the DTCs. INSTALL a new RCM . REFER to Section 501-20B
Ignition OFF. . TEST the system for normal operation. CLEAR the
Ignition ON. DTCs. REPEAT the ABS module self-test
Wait 10 seconds.
the scan tool: Self-Test. INSTALL a new ABS module. REFER to Anti-Lock
Retrieve the continuous memory DTCs Brake System (ABS) Module in this section. TEST
from all modules. the system for normal operation.
Is DTC U0151 or DTC U0151:00 set in
more than one module?
Pinpoint Test H: DTCs C109D, C109E and C109F
Normal Operation
The vacuum sensor is used by the ABS module to determine if hydraulic pump intervention is necessary due
to loss of vacuum. The ABS module sends a 5 volt reference voltage to the sensor, the sensor compares the
pressure in the booster to the ambient air pressure in the engine compartment and sends a varying voltage
back to the ABS module based on the difference between the pressures. Normally, the pressure in the booster
is much lower than ambient air pressure, as the pressure in the booster gets higher (closer to matching ambient
air pressure), the lower the voltage sent back to the ABS module becomes.
When the vacuum in the brake booster falls below a predetermined level, the ABS module commands the
hydraulic pump motor to activate on the next (and any subsequent) brake pedal application to assist with
vehicle braking. The ABS module continues to use the pump motor for braking assist as long as the low
vacuum condition exists.
A 5 volt reference voltage is sent to the sensor, and the sensor output returns to the ABS module.
DTC C109D (Low Vacuum Condition Detected) - This DTC is set when the optimized hydraulic

brake system is activated and does not necessarily indicate a concern with the vacuum sensor, the
related wiring or the ABS module. This DTC most likely indicates a vacuum concern in the brake
booster, engine and any related vacuum hoses/tubes. High altitude locations with low ambient air
temperatures can cause a low vacuum condition to exist in the booster until the engine compartment
warms up.
DTC C109E (Vacuum Sensor Circuit Fault) - If, during normal operation or the ABS module
on-demand self test, the ABS module detects an open circuit, a short to voltage or a short to ground
on the vacuum sensor circuits, DTC C109E is set. Also, a failure of the vacuum sensor causes DTC
C109E to set.
DTC C109F (Vacuum Sensor Signal Fault) - The vacuum sensor has 2 ambient air pressure inlet
ports. If these ports become restricted or clogged, DTC C109F is set.

Vacuum sensor
ABS module
&nbsa>
PINPOINT TEST H: DTCs C109D, C109E AND C109F

H1 CHECK THE ABS MODULE DTCs
Yes
Review the DTCs recorded during Inspection GO to H2 .
and Verification.
Was DTC C109D the only recorded DTC? No
If DTCs C109E and/or C109F were retrieved,
GO to H5 .
For all other DTCs, REFER to the ABS Module

DTC Chart in this section.
H2 CHECK DTC RETURNABILITY
Yes
Using the scan tool, clear the ABS module GO to H3 .
DTCs.
Ignition OFF. No
Disconnect the scan tool. If DTCs C109E and/or C109F were retrieved,
Start the engine. GO to H5 .
NOTE: It may take up to 5 minutes for DTC
C109D to set. For all other DTCs, REFER to the ABS Module
Allow the vehicle to idle for a minimum of 6 DTC Chart in this section.
minutes.
Ignition OFF.
Ignition ON.
Enter the following diagnostic mode on the
scan tool: Self Test - ABS Module.
Is DTC C109D the only vacuum sensor
DTC present?
PINPOINT TEST H: DTCs C109D, C109E AND C109F 2327

H3 CHECK THE ENGINE VACUUM

Yes
Carry out the Intake Manifold Vacuum Test. GO to H4 .
Refer to Diagnosis and Testing in Section
303-00 . No
Does the vacuum gauge indicate normal FOLLOW the diagnostic direction as outlin in
vacuum? Section 303-00 .
H4 CHECK THE SYSTEM FOR A VACUUM
LEAK
Yes
Inspect the following items for correct The condition to set the DTC is not present at
installation, cracks, holes or other damage that this time. CLEAR the DTC. ATTEMPT to
could cause a vacuum leak: recreate the fault by allowing the vehicle to
Vacuum hoses remain overnight in a cold environment.
Vacuum hose connections REPEAT the self-test.
Vacuum sensor seal
Aspirator tube If the DTC returns, INSPECT the items listed
Aspirator tube seal while cold.
Master cylinder-to-booster seal
Vacuum booster If all items check out OK, INSTALL a new
Are the items in good condition and free vacuum sensor. REFER to Section 206-07 .
from leaks? CLEAR the DTC. REPEAT the self-test.
No
REPAIR or INSTALL new as necessary.
CLEAR the DTC. REPEAT the self-test.
H5 CHECK THE BRAKE BOOSTER VACUUM
SENSOR
Yes
Inspect the vacuum sensor ambient air GO to H6 .
pressure inlet ports.
Are both ports free of contamination, debris No
and/or foreign material? INSTALL a new vacuum sensor as necessary.
REFER to Section 206-07 . CLEAR the DTCs.
SENSOR CIRCUITS FOR A SHORT TO
GROUND
Yes
Disconnect: ABS Module C135. GO to H7 .
Measure the resistance between ground and:
brake booster vacuum sensor C149-1, No
circuit VCA38 (BN/VT), harness side. REPAIR the affected circuit(s). CLEAR the
brake booster vacuum sensor C149-2, DTCs. REPEAT the self-test.
circuit RCA37 (WH/BU), harness
side.
brake booster vacuum sensor C149-3,
circuit LCA37 (YE/OG), harness side.


SENSOR CIRCUITS FOR AN OPEN
Yes
Measure the resistance between the ABS GO to H8 .
module C135, harness side and the brake
booster vacuum sensor C149, harness side as No
follows: REPAIR the affected circuit(s). CLEAR the
ABS Vacuum
C135-30 VCA38 C149-1
(BN/VT)
C135-27 RCA37 C149-2
(WH/BU)
C135-26 LCA37 C149-3
(YE/OG)

SENSOR CIRCUITS FOR A SHORT
TOGETHER


brake booster vacuum sensor C149-1, GO to H9 .
circuit VCA38 (BN/VT), harness side
and brake booster vacuum sensor No
C149-2, circuit RCA37 (WH/BU), REPAIR the affected circuit(s). CLEAR the
harness side. DTCs. REPEAT the self-test.
circuit VCA38 (BN/VT), harness side
and brake booster vacuum sensor
C149-3, circuit LCA37 (YE/OG),
harness side.
side, and brake booster vacuum sensor
C149-3, circuit LCA37 (YE/OG),
harness side.

ohms?
H9 CHECK THE ACTIVE BRAKE BOOSTER
Yes
Measure the voltage between ground and: DTCs. REPEAT the self-test.
circuit VCA38 (BN/VT), harness side. No
brake booster vacuum sensor C149-2, GO to H10 .
side.
circuit LCA37 (YE/OG), harness side.

H10 CHECK THE ABS MODULE
CONNECTOR
Yes
Check ABS module C135 for: INSTALL a new ABS module. REFER to
corrosion Anti-Lock Brake System (ABS) Module in this

pushed-out pins section. TEST the system for normal operation.

spread terminals
Connect: ABS Module C135. No
Make sure the connector seats correctly, then The system is operating correctly at this time.
operate the system and verify the concern is The concern may have been caused by a loose or
still present. corroded connector. CLEAR the DTCs.
Is the concern still present? REPEAT the self-test.
Pinpoint Test I: DTC C1996
Normal Operation
The ABS module uses information received from several sensors (wheel speed sensors, steering wheel
rotation sensor, stability control sensors, etc.) to determine if a vehicle instability event is about to occur. If an
event is going to occur, the ABS module adjusts brake torque at specific wheels and the PCM reduces engine
torque to make the vehicle more stable. Once the ABS module has determined that the stability event has been
corrected, it returns brake and engine torque to normal and continues to monitor the vehicle.
DTC C1996 (Active Yaw and/or Roll Control Disabled) - The ABS module monitors the stability
event and is programmed to set DTC C1996 and disable the stability control system if the stability
event lasts longer than 15 seconds.

Steering wheel rotation sensor
Stability control sensor
Wheel speed sensors
ABS module
PINPOINT TEST I: DTC C1996

I1 CHECK FOR ABS DTCs
Yes
Ignition ON. GO to Pinpoint Test P .
Enter the following diagnostic mode on the scan tool: ABS
Module Self-Test. No
Are ABS DTCs C1233, C1234, C1235 or C1236 GO to I2 .
present?
I2 CHECK THE ABS MODULE YAW RATE (YAW_RATE)
PID
Yes
Enter the following diagnostic mode on the scan tool: ABS GO to I3 .
Module DataLogger.
NOTE: The vehicle must be on level ground and at a No
complete standstill. Any vehicle movement results in false GO to I7 .
values for this test.
Monitor the YAW_RATE PID.
Is the YAW_RATE PID value between -0.05 and 0.05?

I3 CHECK THE ABS MODULE LATERAL

ACCELERATION (LAT_ACCL) PID
Yes
NOTE: The vehicle must be on level ground and at a GO to I4 .
complete standstill. Any vehicle movement results in false
values for this test. No
Monitor the LAT_ACCL PID. GO to I7 .
Is the LAT_ACCL PID value between -0.4 and 0.4?
I4 CHECK THE ABS MODULE LONGITUDINAL
ACCELERATION (LONG_ACCL) PID
Yes
Monitor the LONG_ACCL PID. GO to I7 .
Is the LONG_ACCL PID value between -0.4 and 0.4?
I5 CHECK THE ABS MODULE ROLL RATE (ROLLRAT)
PID
Yes
GO to I7 .
Monitor the ROLLRAT PID.
Is the ROLLRAT PID value between -0.05 and 0.05?
I6 CHECK THE STEERING WHEEL ANGLE SENSOR
POSITION (SWA POS) PID
Yes
Monitor the SWA POS PID while rotating the steering GO to I8 .
wheel clockwise and counterclockwise very slowly, from
lock to lock. No
Does the PID change in intervals of 4.5 degrees and GO to Pinpoint Test F .
show a 360-degree increase for each complete
revolution of the steering wheel?
I7 CHECK THE RCM INSTALLATION AND MOUNTING
SURFACE
Yes
Ignition OFF. REPLACE the RCM . REFER to
Depower the Supplemental Restraint System (SRS). Refer Section 501-20B CLEAR the ABS
to Section 501-20B . module DTCs. TEST the system for
After depowering the system, refer to Restraints Control normal
Module (RCM) Removal and Installation in Section
501-20B . Adhere to all safety warnings in the procedure No
while inspecting the RCM for damage or incorrect REINSTALL or REPAIR the RCM
mounting. mounting surface or installation.
Inspect the RCM installation and make sure the nuts are REFER to Section 501-20B .
fully seated and tightened correctly. CLEAR the ABS module DTCs.
Inspect the mounting surface for damage, corrosion or dirt. TEST the system for normal
Is the RCM installed correctly and is the mounting operation.
surface clean and free from damage?
I8 CHECK FOR CORRECT ABS MODULE OPERATION
PINPOINT TEST I: DTC C1996 2332

Disconnect: ABS Module C135. Yes

Check the connector for: INSTALL a new ABS module.
corrosion REFER to Anti-Lock Brake System
pushed-out pins (ABS) Module in this section.
spread terminals CLEAR the DTCs. REPEAT the
Connect: ABS Module C135. self-test.
Make sure the ABS module electrical connector is fully
seated, then operate the system and verify the concern is No
still present. The system is operating correctly at
Is the concern still present? this time. The concern may have
been caused by a loose or corroded
connector. CLEAR the DTCs.
Pinpoint Test J: DTC U0100
Normal Operation
DTC U0100 (Lost Communication With ECM/PCM) - this DTC sets in continuous memory and
on-demand if the brake pedal position switch, and traction control messages that should be received
from the ECM/PCM are missing for 5 seconds or longer.

PCM
ABS module
PINPOINT TEST J: DTC U0100

J1 VERIFY THE SCAN TOOL CAN
COMMUNICATE WITH THE PCM
Yes
Connect the scan tool. GO to J2 .
Check that a vehicle session can be
established using the scan tool. No
Can a vehicle session be established? REFER to Section 418-00 to diagnose no
communication with the PCM.
J2 CHECK THE ABS MODULE
CONTINUOUS MEMORY DTCs
Yes
Ignition ON. GO to J3 .
scan tool: ABS Module Self-Test. No
Car the DTCs. The system is operating correctly at this time. The
Wait 10 seconds. DTC may have been set due to high network traffic
Repeat the ABS module self-test. or an intermittent fault condition.
Is DTC U0100 retrieved again?
PINPOINT TEST J: DTC U0100 2333

J3 RETRIEVE THE RECORDED DTCs

FROM THE PCM KOEO SELF-TEST
Yes
Check for recorded DTCs from the PCM REFER to Section 303-14 .
Key ON Engine OFF (KOEO) self-test.
Is DTC P0562 or P0563 recorded? No
GO to J4 .
J4 CHECK FOR DTC U0100 SET IN OTHER
MODULES
Yes
Ignition ON. INSTALL a new PCM. REFER to Section 303-14 .
Enter the following diagnostic mode on the TEST the system for normal operation.
scan tool: Self-Test.
Retrieve the continuous memory DTCs No
from all modules. INSTALL a new ABS module. REFER to
Is DTC U0100 set in the Transmission Anti-Lock Brake System (ABS) Module in this
Control Module (TCM) (if equipped) or section. TEST the system for normal operation.
DTC U0100 in the Instrument Cluster
(IC)?
Pinpoint Test K: DTC U0101
Normal Operation
DTC U0101 (Lost Communication With Transmission Control Module (TCM)) - sets in continuous
and on-demand memory in the ABS module if data messages received such as the transmission range
info, from the TCM are missing for more than 5 seconds. For a complete list of all network messages,
refer to Section 418-00

TCM
ABS module
PINPOINT TEST K: DTC U0101

K1 VERIFY THE CUSTOMER
CONCERN
Yes
Verify that there is an observable
symptom present. No
Is an observable symptom present? The system is operating normally at this time. The DTC
may have been set due to high network traffic or an
intermittent fault condition.
K2 CHECK THE COMMUNICATION
NETWORK
Yes
PINPOINT TEST K: DTC U0101 2334


Does the TCM pass the network test?
K3 RECHECK THE ABS MODULE DTCs
Yes
Clear the DTCs. GO to K4 .
Wait 10 seconds.
Is DTC U0101 still present? The system is operating correctly at this time. The DTC
may have been set due to high network traffic or an
intermittent fault condition.
K4 CHECK FOR DTC U0101 SET IN
OTHER MODULES
Yes
Clear the DTCs. INSTALL a new TCM . REFER to Transmission
Ignition OFF. Service Components - Exploded View, External
Ignition ON. Components in Section 307-01 . CLEAR the DTCs.
Wait 10 seconds. REPEAT the self-test.
the scan tool: Retrieve All CMDTCs . No
Retrieve the continuous memory DTCs INSTALL a new ABS module. REFER to Anti-Lock
from all modules. Brake System (ABS) Module in this section. TEST the
Is DTC U0101 set in more than one system for normal operation.
module?
Pinpoint Test L: DTC U0114
Normal Operation
DTC U0114 (Lost Communication With Four-Wheel Drive Clutch Control Module [4x4CM]) - sets
in continuous memory if data messages received from the 4X4 control module over the High Speed
Controller Area Network (HS-CAN) are missing for greater than 5 seconds.
4X4 control module

PINPOINT TEST L: DTC U0114
Test Step Result / Action tke

L1 VERIFY THE CUSTOMER CONCERN
Yes
symptom present. No
PINPOINT TEST L: DTC U0114 2335

L2 CHECK THE COMMUNICATION

NETWORK
Yes
Enter the following diagnostic mode on GO to L3 .
the scan tool: Network Test.
Carry out the network test. No
Does the 4X4 control module pass the REFER to Section 418-00 .
network test?
L3 RECHECK THE ABS MODULE DTCs
Yes
Clear the DTCs. Repeat the ABS module GO to L5 .
self-test.
Is DTC U0114 still present? No
The system is operating correctly at this time. The
DTC may have been set due to high network traffic.
L4 CHECK FOR DTC U0102 OR U0114 SET
IN OTHER MODULES
Yes
Clear all DTCs. INSTALL a new 4X4 control module. REFER to
Ignition OFF. Section 308-07A . CLEAR the DTCs. REPEAT the
Wait 10 seconds.
the scan tool: Retrieve All CMDTCs . INSTALL a new IC . REFER to Section 413-01 .
Retrieve the continuous memory DTCs TEST the system for normal operation.
from all modules.
Is DTC U0102 set in the PCM or IC ?
Pinpoint Test M: DTC U0140
Normal Operation
DTC U0140 (Lost Communication With Body Control Module (GEM)) - sets in continuous and
on-demand memory in the ABS module if data messages such as ignition state and ambient
temperature data are missing for more than 5 seconds. For a complete list of all network messages,

Body Control Module (BCM)
ABS Module
PINPOINT TEST M: DTC U0140

M1 VERIFY THE CUSTOMER CONCERN
Yes
Ignition ON. GO to M2 .
symptom present. No
PINPOINT TEST M: DTC U0140 2336

DTC may have been set due to high network traffic or
an intermittent fault condition.
M2 CHECK THE COMMUNICATION
NETWORK
Yes
Enter the following diagnostic mode on GO to M3 .
the scan tool: Network Test.
Carry out the network test. No
Does the BCM pass the network test? REFER to Section 418-00 .
M3 RETRIEVE THE RECORDED DTCs
FROM THE BCM AND ABS MODULE
SELF-TESTS
Yes
Check for voltage-related DTCs from the For the BCM , REFER to Section 419-10 .
self-test.
Is DTC B1318 or DTC B1317 For the ABS module, REFER to DTC Charts in this
recorded? section.
No
GO to M4 .
M4 RECHECK THE ABS MODULE DTCs
Yes
Clear the DTCs. GO to M5 .
Wait 10 seconds.
M5 CHECK FOR DTC U0140:00 SET IN
OTHER MODULES
Yes
Clear the DTCs. INSTALL a new BCM . REFER to Section 419-10 .
Ignition OFF. TEST the system for normal operation. CLEAR the
Wait 10 seconds.
the scan tool: Retrieve All CMDTCs . INSTALL a new ABS module. REFER to Anti-Lock
Retrieve the continuous memory DTCs Brake System (ABS) Module in this section. TEST the
from all modules. system for normal operation.
Is DTC U0140:00 or DTC U0140 set in
Pinpoint Test N: DTCs C1280, C1282, C1516, C2770, U0151, U0452, U1901
Normal Operation
The ABS module uses information received from several sensors (wheel speed sensors, steering wheel
rotation sensor, stability/traction control system sensors, etc.) to determine if vehicle stability, traction or roll

warrants ESC or RSC interaction. If an event is going to occur, the ABS module adjusts the brake torque at
specific wheels and the PCM reduces engine torque to make the vehicle more stable. Once the ABS module
has determined that the stability event has been corrected, it returns the brake and engine torque to normal and
continues to monitor the vehicle. DTCs set in the ignition cycle can only be cleared by cycling the ignition off
and on once the fault has been corrected. The Restraints Control Module (RCM) measures the yaw rate and
vehicle acceleration, then sends the signal through a secondary, dedicated Controller Area Network (CAN) to
the ABS module. This dedicated CAN is used only for communication between the RCM and the ABS
module. The ABS module uses this information for AdvanceTrac and RSC system operation. The ABS
module also compares this information to information it receives from other sensors (brake pedal input,
steering wheel) to determine how valid the information is and to determine if an instability event is about to
occur. The yaw rate sensor, lateral and longitudinal accelerometers are contained in the RCM .
An open circuit or a short to power or ground on any one of the dedicated communication circuits will cause
the ABS module to set a DTC. Also, if the RCM is not mounted in the correct position, with the electrical
connector facing the rear of the vehicle, the ABS module will also set DTCs.

If the ABS module receives a message from the RCM that is out of the normal
C1280 - Yaw operating range or one that does not agree with other sensor information, the
Rate Sensor appropriate signal fault DTC will be set.
Signal Fault
C1282 - Lateral
Accelerometer
Signal Fault
C1516 - Roll
Rate Sensor
Signal Fault
C2770 -
Longitudinal
Acceleration
Sensor Signal
Fault
The RCM uses a dedicated communication bus to send information to the ABS
U0151 - Lost module. If, during normal operation, the ABS module does not receive any
Communication information from the RCM for more than 250 milliseconds, U0151 or U0452 will
with Restraints be set. U0151 monitors both the HS-CAN and the dedicated CAN circuits. If the
Control Module ABS module does not receive the RCM serial number, over the HS-CAN , DTC
(RCM) U0151 sets. It also sets if the sensor data is not received over the dedicated CAN
U0452 - Invalid from the RCM .
Data RecRCM
Sets in continuous memory and on-demand when the ABS module detects an open
U1901 - CAN circuit, a short to voltage or a short to ground on one or both of the dedicated CAN
Network #2 bus circuits or the ABS module does not receive information from the RCM .
Communication
Bus Fault

Wiring, terminals, connectors
RCM
ABS module

PINPOINT TEST N: DTCs C1280, C1282, C1516, C2770, U0151, U0452, U1901

N1 CHECK FOR AN
HS-CAN COMMUNICATION
CONCERN WITH THE RCM
Yes
Connect the scan tool. GO to N2 .
Ignition ON.
NOTE: The network test No
does not test the REFER to Section 418-00 , The Restraints Control Module (RCM)
dedicated CAN Does Not Respond To The Scan Tool.
communications between
the ABS module and
RCM .
Using the scan tool,
carry out the network
test.
Does the RCM pass the
network test?
N2 VERIFY THE RCM
PART NUMBER
Yes
Enter the following GO to N3 .
diagnostic mode on the
scan tool: Log Viewer. No
Retrieve and record the INSTALL the correct RCM . REFER to Section 501-20B . CLEAR
RCM part number from the DTCs. REPEAT the self-test.
the log viewer.
Check the part number
recorded against the
number listed in the Ford
Catalog AdvantageTM
or equivalent.
Does the part number
on the RCM match the
part number listed in
the Ford Catalog
AdvantageTM or
equivalent?
N3 CHECK FOR RCM AND
ABS DTCS
Yes
REFER to Section 501-20B to diagnose the RCM DTCs. TEST the
PINPOINT TEST N: DTCs C1280, C1282, C1516, C2770, U0151, U0452, U1901 2339
Enter the following system for normal operation.

scan tool: Self-Test - No
RCM . If only one of the following ABS module DTCs C1280, C1282,
Enter the following C1516, C2770 was retrieved, GO to N4 .
scan tool: Self-Test - If more than one ABS module DTC C1280, C1282, C1516, C2770
ABS . was retrieved, GO to
Are any RCM DTCs href="SBJ~us~en~file=SBJ69003.HTM~gen~ref.HTM#N8" >N8
retrieved on-demand
self-test?
.
For DTCs U0151 or U0452, GO to N8 .
For all other DTCs, GO to N4 . N4 CHECK THE ABS MODULE YAW RATE (YAW_RATE) PID
Enter the following diagnostic mode on the scan tool: ABS Module DataLogger.
NOTE: The vehicle must be on level ground and at a complete standstill. Any vehicle movement
results in false values for this test.
Monitor the YAW_RATE PID.
Is the YAW_RATE PID value between -0.05 and 0.05?
Yes
GO to N5 .
No
GO to N13 . N5 CHECK THE ABS MODULE LATERAL ACCELERATION (LAT_ACCL) PID
Monitor the LAT_ACCL PID.
Is the LAT_ACCL PID value between -0.4 and 0.4?
Yes
GO to N6 .
No
GO to N13 . N6 CHECK THE ABS MODULE LONGITUDINAL ACCELERATION (LONG_ACCL)
PID
Monitor the LONG_ACCL PID.
Is the LONG_ACCL PID value between -0.4 and 0.4?
Yes
GO to N7 .
No
GO to N13 . N7 CHECK THE ABS MODULE ROLL RATE (ROLLRAT) PID
Monitor the ROLLRAT PID.
Is the ROLLRAT PID value between -0.05 and 0.05?
Yes
GO to N8 .
No
GO to N13 . N8 CHECK THE DEDICATED CAN CIRCUITS FOR AN OPEN
Ignition OFF.
Section 501-20B .
Measure the resistance between the ABS module C135, harness side and the RCM C310B, harness
side as indicated in the following chart:
ABS Module Circuit RCM

C135-18 VCA23 (BU/WH) C310B-20
C135-19 VCA24 (GN/OG) C310B-19
Yes
GO to N9 .
No
REPAIR the affected circuit(s). CLEAR the DTCs. CYCLE the ignition key. REPEAT the self-test. N9
CHECK THE DEDICATED CAN CIRCUITS FOR A SHORT TO GROUND
Measure the resistance between ground and:

ABS module C135-19, circuit VCA24 (GN/OG), harness side.
ABS module C135-18, circuit VCA23 (BU/WH), harness side.
Yes
GO to N10 .
No
REPAIR the affected circuit(s). TEST the system for normal operation. N10 CHECK THE DEDICATED
CAN CIRCUITS FOR A SHORT TOGETHER
Measure the resistance between ABS module C135-19, circuit VCA24 (GN/OG), harness side and
Yes
GO to N11 .
No
REPAIR the affected circuit(s). CLEAR the DTCs. REPEAT the self-test. N11 CHECK THE
DEDICATED CAN CIRCUITS FOR A SHORT TO VOLTAGE
Repower the SRS . Do not prove out the SRS at this time. Refer to Supplemental Restraint System
(SRS) Depowering and Repowering in Section 501-20B .
Ignition ON.
Measure the voltage between ground and:
ABS module C135-19, circuit VCA24 (GN/OG), harness side.
Yes
REPAIR the affected circuit(s) for a short to voltage. CLEAR the DTCs. REPEAT the self-test.
No
GO to N12 . N12 CHECK RCM TERMINATING RESISTOR
Ignition OFF.
Section 501-20B .
Prior to reconnecting any previously disconnected SRS component:
inspect connector(s) (including any in-line connectors) for pushed-out, loose or spread
terminals and loose or frayed wire connections at terminals.
inspect wire harness for any damage, pinched, cut or pierced wires.
inspect RCM C310A and C310B Connector Position Assurance (CPA) lever/lock for correct
operation. Refer to RCM in Section 501-20B .
Refer to Wiring Diagrams Cell 5 , Connector Repair Procedures for schematic and connector
information.
Connect: RCM C310A and C310B.
Measure the resistance between ABS module C135-18, circuit VCA23 (BU/WH), harness side and
C135-19, circuit VCA24 (GN/OG), harness side.
Yes
GO to N13 .
No
INSTALL a new RCM . REFER to Section 501-20B . CLEAR all CMDTCs . PERFORM a road test.
REPEAT the self test. If the concern is still present, GO to N15 . If other DTCs are present, REFER to the
appropriate DTC chart. N13 CHECK THE RCM INSTALLATION AND MOUNTING SURFACE
Ignition OFF.
If not previously directed to do so, depower the Supplemental Restraint System (SRS). Refer to
Supplemental Restraint System (SRS) Depowering and Repowering in Section 501-20B .
Inspect the Restraints Control Module (RCM) installation and make sure that the fasteners are fully
seated and tightened correctly. Refer to RCM in Section 501-20B .
Inspect the mounting surface for damage, corrosion or foreign material.
Is the RCM installed correctly and is the mounting surface clean and free from damage?
Yes
GO to N14 .
No
REPAIR or INSTALL new as necessary. REPOWER the SRS . REFER to Supplemental Restraint System
(SRS) Depowering and Repowering in Section 501-20B . CLEAR all CMDTCs . PERFORM a road test.
REPEAT the self test. N14 CHECK FOR AN INTERMITTENT FAULT

Disconnect: ABS module C135.
inspect connector(s) (including any in-line connectors) for corrosion, loose or spread
terminals and loose or frayed wire connections at terminals.
information.
Connect: All Previously Disconnected Component(s)/Connector(s).
Repower the SRS . Do not prove out the SRS at this time. Refer to Supplemental Restraint System
(SRS) Depowering and Repowering in Section 501-20B .
Perform a road test.
Ignition ON.
Enter the following diagnostic mode on the scan tool: Self Test - ABS Module.
Yes
INSTALL a new RCM . REFER to Section 501-20B . CLEAR all CMDTCs . PERFORM a road test.
REPEAT the self test. If the concern is still present, GO to N15 . If other DTCs are present, REFER to the
appropriate DTC chart.
No
The fault is not present and cannot be recreated at this time. Do not install any new SRS components at this
time. SRS components should only be installed when directed to do so in the pinpoint test. N15
CHECK THE ABS MODULE FOR CORRECT OPERATION Depower the SRS . Refer to Supplemental
Restraint System (SRS) Depowering and Repowering in Section 501-20B .
Prior to reconnecting any previously disconnected SRS component:
inspect connector(s) (including any in-line connectors) for pushed-out, loose or spread terminals and
loose or frayed wire connections at terminals.
inspect RCM C310A and C310B CPA lever/lock for correct operation. Refer to RCM in Section
501-20B .
inspect ABS module C135 for dirt, corrosion, water intrusion, pushed-out, loose or spread terminals
and loose or frayed wire connections at terminals.
information.
Connect: All Previously Disconnected Component(s)/Connector(s).

Repower the SRS . Do not prove out the SRS at this time. Refer to Supplemental Restraint System (SRS)
Depowering and Repowering in Section 501-20B .
Perform a road test.
Ignition ON.
Enter the following diagnostic mode on the scan tool: Self Test - ABS Module.
Yes
INSTALL a new ABS module. REFER to Anti-Lock Brake System (ABS) Module in this section.
No
The system is operating correctly at this time. The concern may have been caused by a loose or corroded
connector.
Pinpoint Test O: DTC U0155
Normal Operation
DTC U0155 (Lost Communication With Instrument Cluster (IC) Control Module) - sets in continuous
and on-demand memory in the ABS module if data messages such as traction control switch and hill
descent switch messages are missing for more than 5 seconds. For a complete list of all network
messages, refer to Section 418-00 .

ABS Module
PINPOINT TEST O: DTC U0155

O1 VERIFY THE CUSTOMER CONCERN
Yes
Ignition ON. GO to O2 .
symptom present. No
O2 CHECK THE COMMUNICATION
NETWORK
Yes
Ignition ON. GO to O3 .
Does the IC pass the network test?
O3 RETRIEVE THE RECORDED DTCs
FROM THE IC SELF-TESTS
Yes
Check for recorded IC DTCs from the REFER to Section 413-01 .
self-test.
Is DTC U3003:16 (or B1318) or DTC No
U3003:17 (or B1317) recorded? GO to O4 .
O4 RECHECK THE ABS MODULE DTCs
Yes
Clear the DTCs. GO to O5 .
Wait 10 seconds.
O5 CHECK FOR DTC U0155 SET IN
OTHER MODULES
Yes
Clear the DTCs. INSTALL a new IC . REFER to Section 413-01 .
Ignition OFF. TEST the system for normal operation. CLEAR the
PINPOINT TEST O: DTC U0155 2345


Wait 10 seconds.
the scan tool: Self-Test. INSTALL a new ABS module. REFER to Anti-Lock
Retrieve the continuous memory DTCs Brake System (ABS) Module in this section. TEST
from all modules. the system for normal operation.
Is DTC U0155:00 or DTC U0155 set in
Pinpoint Test P: Unintended ABS Activation, ABS Too Sensitive, ABS Activates on a Normal Stop
Normal Operation
The wheel speed sensor and sensor tone ring generate a signal to the ABS module that is proportional to
wheel speed. The ABS module compares the wheel speed inputs from all wheel speed sensors to determine an
impending wheel lockup.

When the vehicle speed exceeds 20 km/h (12 mph), if the ABS module does not
C1233 - LF receive a signal from the wheel speed sensor, the appropriate DTC is set. These DTCs
Wheel Speed are usually set by a damaged wheel speed sensor or damaged sensor tone ring, they
Sensor Input can also be set by wheels and/or tires of different sizes being installed on the vehicle.
Signal
Missing
C1234 - RF
Wheel Speed
Sensor Input
Signal
Missing
C1235 - RR
Wheel Speed
Sensor Input
Signal
Missing
C1236 - LR
Wheel Speed
Sensor Input
Signal
Missing

Front/rear suspension concern
Parking brake shoes out of adjustment (dragging)
Wheel speed sensor ring
Wheel speed sensor
ABS module

PINPOINT TEST P: UNINTENDED ABS ACTIVATION, ABS TOO SENSITIVE, ABS ACTIVATES ON A NORMAL
STOP
NOTE: Anytime a wheel speed sensor is removed, thoroughly clean the mounting surfaces and apply a thin
coating of grease.

P1 CHECK THE SUSPENSION
Yes
Inspect the front and rear suspension for signs of wear REFER to Section 204-01A , Section
or damage. Refer to Section 204-01A , Section 204-01B or Section 204-02 to repair the
204-01B or Section 204-02 . concern. TEST the system for normal
Are any suspension concerns found? operation after the repair.
No
GO to P2 .
P2 CHECK THE PARKING BRAKE ADJUSTMENT
Yes
Disengage the parking brake. REFER to Section 206-05 to repair the
Inspect the parking brake shoes for correct concern. TEST the system for normal
adjustment. Refer to Section 206-05 . operation after the repair.
Are any parking brake concerns found?
No
GO to P3 .
P3 CHECK THE ABS MODULE DTCs
Yes
Review the ABS module DTCs retrieved and GO to Pinpoint Test D .
recorded during Inspection and Verification.
Is DTC C1145, C1155, C1165 or C1175 also No
present? GO to P4 .
P4 MONITOR THE WHEEL SPEED SENSOR PIDs

Ignition ON.
DataLogger - ABS Module .
While driving the vehicle at the speed at which the
concern occurred, monitor the following PIDs:
Left Front Wheel Speed Sensor (LF_WSPD)
Right Front Wheel Speed Sensor
(RF_WSPD)
Left Rear Wheel Speed Sensor (LR_WSPD)
Right Rear Wheel Speed Sensor (RR_WSPD)
Are the wheel speed PIDs consistent with the
vehicle speed and each other?
Yes
CLEAR the DTCs. DRIVE the vehicle. REPEAT the self-test.
PINPOINT TEST P: UNINTENDED ABS ACTIVATION, ABS TOO SENSITIVE, ABS ACTIVATES
2347
ON A NO
RETRIEVE and RECORD any ABS module DTCs.
If DTC C1233, C1234, C1235 or C1236 returns, GO to P10 .
For all other ABS module DTCs, REFER to the ABS Module
DTC Chart.
If no DTCs return, INSPECT the ABS module and wheel

speed sensor connectors for corrosion, pushed-out pins, or
spread terminals and REPAIR as necessary. The concern may
have been caused by a loose or corroded connector.
No
If the Rotunda Active Wheel Speed Sensor Tester is available,
GO to P5 .
If the Rotunda Active Wheel Speed Sensor Tester is not

available, GO to P7 .
P5 CHECK THE ABS MODULE OUTPUT USING THE
ROTUNDA ACTIVE WHEEL SPEED SENSOR
TESTER
Yes
Ignition OFF. GO to P6 .
Connect the Active Wheel Speed Sensor Tester to the No
wheel speed sensor connectors. GO to P8 .
Select the correct system polarity on the Active Wheel
Speed Sensor Tester and turn the power switch to the
ON position.
Ignition ON.
Is the module output LED illuminated?
P6 CHECK THE WHEEL SPEED SENSOR OUTPUT
WITH THE ROTUNDA ACTIVE WHEEL SPEED
SENSOR TESTER
Yes
Raise the suspect wheel until it can spin freely. Refer INSPECT the wheel speed sensor tone
to Section 100-02 . ring for damage and looseness.
While monitoring the Active Wheel Speed Sensor INSTALL new components as necessary.
Tester, slowly spin the suspect wheel. If the tone ring is OK, the concern may
Do the sensor output LEDs illuminate and flash have been caused by a loose or corroded
and is the current overload LED not illuminated? connector. CLEAR the DTCs. REPEAT
the self-test.
No
If the current level LED is not
illuminated and the sensor output LEDs
do not illuminate or if the current level
LED is illuminated red, INSTALL a new
wheel speed sensor. REFER to Wheel
Speed Sensor - Front or Wheel Speed
Sensor - Rear in this section. CLEAR the
2348
ON A NO
If the current level LED is not

illuminated and the sensor output LEDs
illuminate green but do not flash,
INSPECT the wheel speed sensor tone
ring and INSTALL new if necessary. If
the tone ring is OK, INSTALL a new
wheel speed sensor. REFER to Wheel
Speed Sensor - Front or Wheel Speed
Sensor - Rear in this section. CLEAR the
P7 CHECK THE ABS MODULE OUTPUT
NOTE: If the 2 wheel speed sensor circuits are

shorted together, the ABS module shuts down those
circuits and no voltage is present at the connectors. If
this happens, cycle the ignition key and take the
measurement again, being careful not to short the 2
wheel speed sensor circuits together.

Ignition ON.
For DTC C1234 , measure the voltage between RF
wheel speed sensor C160-2, circuit VCA05 (GY/VT),
harness side and RF wheel speed sensor C160-1,
circuit RCA19 (VT), harness side.
For DTC C1233 , measure the voltage between LF
wheel speed sensor C150-2, circuit VCA03 (VT/WH),
harness side and LF wheel speed sensor C150-1, Yes
circuit RCA17 (YE), harness side. GO to P9 .
For DTC C1235 , measure the voltage between RR
wheel speed sensor C426-2, circuit VCA06 No
(WH/OG), harness side and RR wheel speed sensor GO to P8 .
C426-1, circuit RCA20 (BN), harness side.
For DTC C1236 , measure the voltage between LR
wheel speed sensor C440-2, circuit VCA04 (BU/OG),
harness side and LR wheel speed sensor C440-1,
circuit RCA18 (BN/GN), harness side.

P8 CHECK THE WHEEL SPEED SENSOR CIRCUITS
FOR AN OPEN
2349
ON A NO
NOTE: Both circuits must be checked for each DTC. Yes

GO to P12 .
Ignition OFF.
Disconnect: ABS Module C135. No
Disconnect: Suspect Wheel Speed Sensor. REPAIR the affected circuit(s). CLEAR
Measure the resistance between the ABS module the DTCs. REPEAT the self-test.
connector, harness side and the suspect wheel speed
sensor connector, harness side as follows:
ABS Wheel Speed

DTC C1233
C135-45 VCA03 C150-2
(VT/WH)
C135-46 RCA17 (YE) C150-1
DTC C1234
C135-34 VCA05 (GY/VT) C160-2
C135-33 RCA19 (VT) C160-1
DTC C1235
C135-43 VCA06 C426-2
(WH/OG)
C135-42 RCA20 (BN) C426-1
DTC C1236
C135-36 VCA04 (BU/OG) C440-2
C135-37 RCA18 (BN/GN) C440-1

P9 CHECK THE WHEEL SPEED SENSOR AND
MOUNTING
Yes
With the gear selector in NEUTRAL, position the GO to P11 .
vehicle on a hoist. Refer to Section 100-02 .
Inspect the wheel speed sensor for looseness. No
Is the wheel speed sensor and mounting OK? TIGHTEN the wheel speed sensor to
specification, REFER to Specifications in
this section. CLEAR the DTCs. GO to
P10 .
P10 RECHECK THE WHEEL SPEED SENSOR PIDs
Yes
While driving the vehicle at a constant speed, monitor The system is operating correctly at this
the following PIDs: time. The concern may have been caused
Left Front Wheel Speed Sensor (LF_WSPD) by a loose wheel speed sensor.
(RF_WSPD) No
Left Rear Wheel Speed Sensor (LR_WSPD) GO to P11 .
Right Rear Wheel Speed Sensor (RR_WSPD)
2350
ON A NO
Are all the wheel speed sensor PIDs consistent with

the vehicle speed and each other?
P11 CHECK THE WHEEL SPEED SENSOR(S) FOR
DAMAGE
Yes
Ignition OFF. INSTALL a new wheel hub and bearing
With the gear selector in NEUTRAL, position the (wheel speed sensor tone rings are part of
vehicle on a hoist. Refer to Section 100-02 . the wheel hub and bearing assembly).
Remove the wheel speed sensor. Refer to Wheel REFER to Section 204-02 . CLEAR the
Speed Sensor - Front or Wheel Speed Sensor - Rear in DTCs. REPEAT the self-test.
this section.
NOTE: Examine the wheel speed sensor wire No
carefully, using a good light source. Failure to verify INSTALL a new wheel speed sensor.
damage in the wheel speed sensor wire can lead to REFER Wheel Speed Sensor - Front or
unnecessary installation of a new component. Wheel Speed Sensor - Rear in this
Inspect the wheel speed sensor and attached wire section. CLEAR the DTC. REPEAT the
harness for general damage. self-test.
Is the wheel speed sensor and harness OK?
P12 CHECK FOR CORRECT ABS MODULE
OPERATION
Yes
Ignition OFF. INSPECT the wheel speed sensor tone
Disconnect: ABS Module C135. ring for damage. INSTALL new
Check ABS module C135 for: components as necessary. If the tone ring
corrosion is OK, INSTALL a new ABS module.
pushed-out pins REFER to Anti-Lock Brake System
spread terminals (ABS) Module in this section. TEST the
Connect: ABS Module C135. system for normal operation.
Make sure the connector seats correctly, then operate
the system and verify the concern is still present. No
Is the concern still present? The system is operating correctly at this
time. The concern may have beensed by a
loose or corroded connector. CLEAR the
Pinpoint Test Q: The Stability/Traction Control System Cannot Be Disabled
Normal Operation
The traction control system operates using the ABS module to interact with the PCM to reduce engine torque
if one or more of the drive wheels lose traction and begin to spin during acceleration. Engine torque
modulation is achieved by regulating fuel and spark to the cylinders.
The stability control utilizes several sensor inputs (wheel speed, steering wheel rotation, stability sensors,
brake pedal) to monitor the vehicle motion relative to the intended course. If the system determines that a
vehicle instability event is about to occur, it takes action to adjust brake torque at specific wheels and to
reduce engine torque to reduce the cornering forces and, therefore, the total roll moment acting on the vehicle.
If a MyKey-restricted key is in use that has the AdvanceTrac always-on feature configured "on", the
stability/traction control system cannot be disabled.

The stability/traction control switch is a momentary contact switch and is part of the liftgate release and
hazard switch assembly. When the switch is disabled, the ABS module is momentarily grounded through the
switch. The ABS module then sends a message to the PCM along the High Speed Controller Area Network
(HS-CAN) disable the traction control function. The ABS module also sends a message over the HS-CAN to
the Instrument Cluster (IC) to illuminate the stability/traction control indicator (sliding-car icon).

Stability/traction control switch
ABS module
PINPOINT TEST Q: THE STABILITY/TRACTION CONTROL SYSTEM CANNOT BE DISABLED

Q1 VERIFY THAT THE KEY IN USE IS NOT
MYKEY-RESTRICTED
Yes
Ignition ON. INFORM the customer that the key in
Attempt to disable the Electronic Stability Control use is MyKey-restricted. If necessary,
(ESC) system by pressing the stability/traction control REFER to the Owner's Literature for
switch. information regarding the programming
Is ADVTRAC ON MY KEY SETTING displayed in of MyKey features.
the message center?
No
PRESS the stability/traction control
switch again and GO to Q2 .
QHECK THE ABS MODULE STABILITY/TRACTION
CONTROL SWITCH (TCYC_SW) PID
Yes
Connect the scan tool. GO to Q6 .
Ignition ON.
ABS Module DataLogger. GO to Q3 .
NOTE: Press and hold the switch for at least one
second.
Monitor the TCYC_SW PID while pressing and
releasing the stability/traction control switch.
Does the PID agree with the switch position?
Q3 CHECK THE STABILITY/TRACTION CONTROL
ON/OFF CIRCUIT FOR AN OPEN
Yes
Ignition OFF. GO to Q4 .
Disconnect: Stability/Traction Control Switch C2361.
Disconnect: ABS Module C135. No
Measure the resistance between ABS module C135-4, REPAIR circuit CCA15 (YE/GY).
circuit CCA15 (YE/GY), harness side and TEST the system for normal operation.
stability/traction control switch C2361-2, circuit
CCA15 (YE/GY), harness side.

2352

SWITCH GROUND CIRCUIT FOR AN OPEN
Yes
Measure the resistance between stability/traction GO to Q5 .
control switch C2361-4, circuit GD138 (BK/WH),
REPAIR circuit GD138 (BK/WH).

SWITCH FOR AN OPEN
Yes
Measure the resistance between stability/traction GO to Q6 .
control switch C2361, pin 2 and pin 4, component side
while pressing and releasing the switch. No
Is the resistance greater than 10,000 ohms with the INSTALL a new stability/traction
switch released and less than 5 ohms with the switch control switch. REFER to
pressed? Stability/Traction Control Switch -
Expedition or Stability/Traction Control
Switch - Navigator in this section. TEST
Q6 CHECK FOR CORRECT ABS MODULE
OPERATION
Yes Anti-Lock Brake System (ABS)
Check ABS module C135 for: Module in this section. TEST the system
corrosion for normal operation.
pushed-out pins
spread terminals No
Connect: ABS Module C135. The system is operating correctly at this
Make sure the connector seats correctly, then operate time. The concern may have been
the system and verify the concern is still present. caused by a loose or corroded
Is the concern still present? connector. CLEAR the DTCs. REPEAT
the self-test.
Pinpoint Test R: DTC C1288

2353
Normal Operation
The ABS module monitors the pressure of the hydraulic brake system through the use of a brake pressure
transducer. The transducer sends a signal to the ABS module that varies in relation to the amount of pressure
applied to the brake pedal. The more pressure that is applied, the greater the signal send to the ABS module.
The brake pressure transducer is internal to the Hydraulic Control Unit (HCU) and cannot be serviced
separately. If a new brake pressure transducer is needed, a new HCU must be installed.
DTC C1288 (Pressure Sensor Main/Primary Input Circuit Failure) - If there is an incorrect connection
between the ABS module and HCU , if the brake pressure transducer is faulted or if the ABS module
is faulted internally, this DTC sets.

ABS module
HCU
PINPOINT TEST R: DTC C1288

R1 CHECK FOR FAULT REPEATABILITY
Yes
Connect the scan tool. GO to R2 .
Ignition ON.
Using the scan tool, clear the ABS module DTCs. No
Drive the vehicle at least 20 km/h (12 mph). INSPECT the ABS module and HCU for
Enter the following diagnostic mode on the scan tool: damage. REPAIR or INSTALL new as
ABS Module Self Test. necessary. If any other DTCs are
Is DTC C1288 present? retrieved, REFER to the ABS Module
R2 VERIFY THE ABS MODULE FASTENERS ARE
TIGHTENED CORRECTLY
Yes
Ignition OFF. GO to R3 .
Loosen each ABS module fastener and tighten to the
correct torque specification. Refer to Anti-Lock No
Brake System (ABS) Module in this section for the The system is operating correctly at this
correct torque specification. time. The concern may have been caused
Ignition ON. by an incorrectly installed ABS module.
Using the scan tool, clear the ABS module DTCs. RETURN the vehicle to the customer.
Drive the vehicle at least 20 km/h (12 mph).
ABS Module Self Test.
Is DTC C1288 present?
R3 MONITOR THE PRESSURE TRANSDUCER
(XDUCERCAL) PID
Yes
Disconnect: ABS Module C135. Anti-Lock Brake System (ABS) Module

Separate the ABS module from the HCU . Refer to in this section. CLEAR the DTCs.
Anti-Lock Brake System (ABS) Module in this REPEAT the self test.
section.
Connect: ABS Module C135 . No
Ignition ON. INSTALL a new HCU . REFER to
Enter the following diagnostic mode on the scan tool: Hydraulic Control Unit (HCU) in this
ABS Module DataLogger. section. CLEAR the DTCs. REPEAT the
With the ABS module separated from the HCU , self test.
monitor the XDUCERCAL PID.
Does the PID read less than 19,000 kPa (2,756
psi)?
PINPOINT TEST R: DTC C1288 2355

08/12/2010
Special Tool(s)

Material
Item Specification
(Canada)

1 2B523 Rear combination valve brake tube
2 2264 LH front brake tube
3 2C405 Hydraulic Control Unit (HCU)
4 2A040 Master cylinder primary brake tube
5 2263 RH front brake tube
6 2B523 Rear combination valve brake tube
Hydraulic Control Unit (HCU) 2356

7 2B253 Master cylinder secondary brake tube

8 - ABS module electrical connector (part of 14A464)
9 2C346 HCU -to-bracket bolt (3 required)

NOTE: On vehicles equipped with Roll Stability Control (RSC), the ABS module and the Hydraulic
Control Unit (HCU) calibrated to one another. Do not swap ABS modules between RSC -equipped vehicles.
1. If a new ABS module and HCU are being installed, connect the scan tool and upload the module
configuration information. For additional information, refer to Section 418-01 .
2. Disconnect the ABS module electrical connector.
3. NOTICE: Only authorized inlet hydraulic brake tubes should be used. These tubes are of
specific design and only authorized parts should be used when installing new inlet brake tubes.
Use of other than authorized inlet brake tubes may result in damage to the components.
NOTE: Plug each open port to prevent brake fluid from spilling.
Disconnect the 6 brake tube fittings.
To install:
Tighten the master cylinder brake tube fittings to 25 Nm (18 lb-ft).
Tighten the remaining brake tube fittings to 20 Nm (177 lb-in).
4. Remove the 3 HCU -to-bracket bolts and the HCU .


Bleed the brake system. For additional information, refer to Section 206-00 .
6. If a new ABS module and HCU were installed, download the configuration information from the scan
tool. For additional information, refer to Section 418-01 .


08/12/2010
Anti-Lock Brake System (ABS) Module
Special Tool(s)

Part
1 - Air Cleaner (ACL) outlet clamp (part of 9F805)
2 - Mass Air Flow (MAF) sensor electrical connector (part
of 14A464)
3 9661 ACL housing cover

4 W302577 ABS module bolts (4 required)
Anti-Lock Brake System (ABS) Module 2359

5 2C219 ABS module

6 - ABS module electrical connector (part of
14A464)
7 W505434 Hydraulic Control Unit (HCU)
bracket-to-frame bolts (3 required)
NOTE: On vehicles equipped with Roll Stability Control (RSC), the ABS module and the Hydraulic
Control Unit (HCU) are calibrated to one another. Do not swap ABS modules between RSC -equipped
vehicles.
1. If installing a new ABS module, connect the scan tool and upload the configuration information. For
2. Release the Air Cleaner (ACL) cover retaining clips and disconnect the Mass Air Flow (MAF) sensor
3. Loosen the ACL outlet clamp and disconnect the ACL cover from the outlet pipe.
4. Remove the 3 HCU bracket-to-frame bolts.

5. Disconnect the ABS module electrical connector.
6. Remove the 4 ABS module bolts and the ABS module.

8. If installing a new ABS module, download the configuration information from the scan tool. For
additional information, refer Section 418-01 .
9. If installing a new ABS module, calibrate the stability control sensor cluster sensor. Connect the scan
tool and carry out the IVD Initialization sequence.


08/12/2010
Wheel Speed Sensor - Front

1 - Front wheel speed sensor electrical connector
(part of 14250)
2 W710279 Front wheel speed sensor harness bolt
3 - Front wheel speed sensor bolt (part of 2C204)
5 2B120 RH / 2B121 Brake caliper
LH
6 1125 Brake disc
7 2C204 Front wheel speed sensor
3. Remove the wheel speed sensor harness bolt and detach the retainers.
4. Support the caliper with mechanic's wire.

Wheel Speed Sensor - Front 2362

6. Remove the front wheel speed sensor bolt and the sensor.
Wheel Speed Sensor - Front 2363

08/12/2010
Wheel Speed Sensor - Rear

1 - Rear wheel speed sensor bolt (part of 2C190)
2 2C190 Rear wheel speed sensor
3 - Body harness electrical connector (part of 14A464)
1. Remove the parking brake shoes. For additional information, refer to Section 206-05 .
2. Disconnect the wheel speed sensor harness from the retaining clips.
3. Remove the rear wheel speed sensor bolt and the sensor.
Wheel Speed Sensor - Rear 2364

Wheel Speed Sensor - Rear 2365

08/12/2010
Steering Wheel Rotation Sensor
Part
1 - Steering wheel rotation sensor electrical connector (part
of 14489)
2 N802141 Steering wheel rotation sensor bolt (2 required)
3 3F818 Steering wheel rotation sensor
1. Disconnect the steering wheel rotation sensor electrical connector.
2. Remove the 2 bolts and the steering wheel rotation sensor.

4. NOTE: If the sensor is not calibrated after installation, a DTC will be set in the ABS module.
Calibrate the sensor in the following sequence:
1. Start the engine.

2. Rotate the steering wheel from lock to lock a minimum of 2 times.
Steering Wheel Rotation Sensor 2366

Steering Wheel Rotation Sensor 2367

08/12/2010
Stability/Traction Control Switch - Expedition
1. Refer to Hazard Flasher Lamp Switch in Section 417-01 .
Stability/Traction Control Switch - Expedition 2368

08/12/2010
Stability/Traction Control Switch - Navigator

1 - Instrument panel center finish panel screws (2
required)
2 04302 Stability/traction control switch assembly
3 13350 Lower instrument panel center finish panel
4 - Electrical connector (part of 14401)
1. Apply the parking brake and move the shift lever to NEUTRAL.
2. Remove the shift lever trim ring.
4. Remove the lower instrument panel finish panel in the following sequence.
1. Remove the 2 lower instrument panel finish panel screws.
2. Pull out on the panel to disengage the clips.
5. Press the nd remove the stability/traction control switch assembly.
Stability/Traction Control Switch - Navigator 2369


SECTION 307-01: Automatic Transaxle/Transmission - 2011 Expedition, Navigator Workshop

6R80 Manual
Material

Capacity
Dye-Lite ATF/Power Steering - -
Fluid Leak Detection Dye
164-R3701 (Rotunda)
Motorcraft MERCON LV MERCON 12.30L
Automatic Transmission Fluid LV (13.0 qt)
XT-10-QLVC
Motorcraft XL-5 (aerosol) and/or
CRC SL3151
Item Specification
Fluid
NOTICE: Transmission fluids are not
interchangeable. The use of any other
fluid or cleaning agents will cause
internal transmission damage.
Normal maintenance: uare">

Transmission fluid change not
necessary, filled for life.
Severe duty maintenance:
Change the transmission fluid

at 24,000 km (150,000 mi)
intervals.
Fluid Filter
Internal to the transmission -
Assembly Weight
Description Specification
Transmission 80.24 kg (215 lb)

Clutch Application Chart
Gear Forward (A) Direct (B) Intermediate (C) Low/Reverse (D) Overdrive (E)
Park X
Reverse X X
Neutral X 1st Gear Manual X X
2nd Gear Manual X X
3rd Gear Manual X X
1st Gear D X X
2nd Gear D X X
3rd Gear D X X
4th Gear D X X
5th Gear D X X
6th Gear D X X
Clutch Application Chart
SSB (VFS2) SSD (VFS4) PCA (VFS5) SSE

SSA (VFS1) Inversely SSC (VFS3) Inversely Inversely TCC (VFS6) (SS1)
Gear Proportional Proportional Proportional Proportional Proportional Proportional ON/OFF
Park X a
Reverse X X a
Neutral X a
1st Gear X X a a
Manual
2nd X X a a
Gear
Manual
3rd X X a a
Gear
Manual
1st Gear X X a a
D
2nd X X a a
Gear D
3rd X X a a
Gear D
4th X X a a X
Gear D
5th X X a a X
Gear D
6th X X a a X
Gear D

a Transmission control module (TCM) controlled
Gear Ratio
1st 4.17 to 1
2nd 2.34 to 1
3rd 1.52 to 1
4th 1.14 to 1
5th 0.87 to 1
6th 0.69 to 1
Reverse 3.40 to 1
Stall Speed
Engine Min Max

5.4L 3V 2,269 2,677
End Play
NOTE: All friction and steel plates use a wave design plate.
Item Specifications
Forward Clutch (A) 0.71-1.10 mm
(0.028-0.043 in)
Direct Clutch (B) 0.50-1.30 mm
(0.019-0.051 in)
Intermediate Clutch (C) 0.71-1.10 mm
(0.028-0.043 in)
Low/Reverse Clutch (D) 1.0-1.6 mm
(0.039-0.063 in)
Overdrive (O/D) Clutch (E) 0.50-0.90 mm
(0.019-0.035 in)
Clutch Plate Quantity
Component

Number of Number of Separator Plate Number of Pressure Plate

Frictions Separator Plates Thickness Pressure Plates Thickness
Forward Clutch 5 6 3.0 mm 1 3.0 mm
(A)
(0.11 in) (0.11 in)
Direct Clutch (B) 5 5 2.1 mm 1 3.9 mm
(0.08 in) (0.15 in)

Intermediate 5 5 3.0 mm 1 3.9 mm
Clutch (C)
(0.11 in) (0.15 in)
Low/Reverse (D) 6 6 2.1 mm Select 5.4 mm
(0.08 in) (0.21 in)

Select 5.7 mm
(0.22 in)
2.1 mm Select 6.0 mm
(0.08 in) (0.23 in)

Overdrive (O/D) 6 6 6.15 mm 1 3.0 mm
Clutch (E)
(0.24 in) (0.11 in)
Shift Speeds
NOTE: Shift speed ranges are approximate for all applications. For specific applications (engine, axle ratio,
tire size and application), refer to the Automatic Transmission Specification booklet.
Always drive the vehicle in a safe manner according to driving conditions and obey all traffic laws.
Throttle Position Shift MPH Km/H

Light Throttle 1-2 8-13 13-21
Throttle Position Sensor Voltage 2-3 16-21 26-34
3-4 22-27 35-43
4-5 35-40 56-64
1.25 Volts 5-6 44-49 71-79
Closed Throttle 6-5 35-40 56-64
5-4 25-30 40-48
4-3 8-13 13-21
3-2 2-7 3-11
2-1 1-4 2-6
Wide Open Throttle 1-2 28-33 45-53
2-3 54-59 87-95
3-4 87-92 140-148


Detent spring bolts 12 - 106
Dual converter Y-pipe bolts 40 30 -
Evaporative Emission (EVAP) canister assembly bolt 20 - 177
Exhaust flange nuts 40 30 -
Exhaust heat shield bolt 15 - 133
Flexplate inspection cover bolts 35 26 -
Front pump body bolts 15 - 133
Front pump-to-case bolts 10 - 89
Fuel line bracket bolt 25 18 -
Ground wire nut 23 17 -
LH isolator cap bolt 35 26 -
Manual control lever nut 18 - Mechatronic assembly bolts a - - -
Mechatronic assembly-to-transmission case bolts a - - -
Output shaft flange nut 80 59 -
Park pawl pin bolt 23 17 -
Park rod actuating plate 12 - 106
Selector lever cable bracket bolts 48 35 -
Skid plate bolts 40 30 -
Solenoid bracket bolts 6 - 53
Starter B+ cable 12 - 106
Starter cable (small) 6 - 53
Starter motor bolts 26 19 -
Torque converter nuts 35 26 -
Transmission case bolts 48 35 -
Transmission crossmember nuts and bolts 90 66 -
Transmission fluid cooler tube bracket bolt 23 17 -
Transmission fluid cooler tube bracket front stud bolt nut 27 20 -
Transmission fluid fill plug 35 26 -
Transmission fluid pan bolts a - - -
Transmission insulator and retainer bolts 90 66 -
Transmission insulator and retainer nuts 115 85 -



6R80 Manual
Transmission Description
6R80 Transmission
This transmission has an internal thermal bypass valve contained within the case.
This transmission uses planetary gears with hydraulic electronic controls. The Transmission Control Module
(TCM) and the main control valve body units form a composite element that is installed as a single unit inside
the automatic transmission.
This transmission has the following features:
Six forward speeds

Torque converter with an integral converter ch
Electronic shift and pressure controls
Single planetary gear set
Double planetary gear set
Two fixed multi-disc clutches
Three multi-plate clutches
All hydraulic functions are directed by electronic solenoids to control the following:
Engagement feel
Shift feel
Shift scheduling
Modulated Torque Converter Clutch (TCC) applications
This transmission has a mechatronic unit which contains:
Transmission Control Module (TCM)

Turbine Shaft Speed (TSS) sensor
Output Shaft Speed (OSS) sensor
An internal P, R, N, D selector shaft position sensor
Transmission Fluid Temperature (TFT) sensor
Transmission Description 2377

Engine power reaches the transmission by a torque converter with an integral clutch. The 6 forward gears and
one reverse gear are obtained from 2 planetary gearsets.
This automatic transmission is a 6-speed electronically controlled transmission comprising the basic elements
of a TCM , main control valve body unit, torque converter, 1 solenoid valve and 6 pressure regulators. Gear
selection is achieved by the control of automatic transmission fluid flow to operate various internal clutches.
The TCM operates the electrical components and provides for the control of gear selection shift pressure,
which increases refinement and torque converter slip.
In the event of a system fault, the TCM also provides for Failure Mode Effect Management to maintain
maximum functional operation of the transmission with a minimum reduction in driver, passenger or vehicle
safety. In the event of a total loss of control or electrical power, the basic transmission functions P, R, N and
D are retained. Also 3rd or 5th gear is retained by the hydraulic system. The gear retained is dependent upon
the gear selected at the time of the failure.
6R80 Transmission 2378


6R80 Manual
Identification Tags
All vehicles come equipped with a Safety Compliance Certification Label. The location on the label marked
TR is reserved for the transmission code. To determine the correct transmission for this vehicle, refer to the
Owner's Literature, Transmission Code Designations. All transmissions are equipped with an identification
tag located on the transmission case. For transmission part number, serial number and build date, refer to the
transmission identification tag located on the transmission case.
Item Description
1 Part number
2 Build date
3 Serial number
Identification Tags 2379


6R80 Manual
Major Components
Major Components
This transmission has the following major components:
Transmission case with integral torque converter housing and extension housing
Torque converter
Fluid pump
Three drive clutches:
Forward clutch (A)
Direct clutch (B)
Overdrive (O/D) clutch (E)
Two brake clutches:
Intermediate clutch (C)
Low/reverse clutch (D)
Two planetary gearsets:
Front single planetary gearset (1 sun gear, 1 carrier, 1 ring gear)
Rear ravigenaux planetary gearset (2 sun gears, 1 carrier with 2 sets of pinion gears and 1 ring
gear)
Main control (mechatronic assembly):
Upper valve body
Lower e body
Transmission Range (TR) sensor
Turbine Shaft Speed (TSS) sensor
Output Shaft Speed (OSS) sensor
NOTE: Friction and steel plate quantity will vary based on engine displacement. Refer to the Clutch Plate
Quantity Chart in the Specifications portion of this section.
In addition to the torque converter, the other shift elements are:
three rotating multi-plate clutches: forward (A), direct (B) and overdrive (E).
two fixed multi-disc brakes: intermediate (C) and low/reverse (D).
All gear shifts from 1st to 6th or from 6th to 1st are power-on overlapping shifts. That is, during the shift, one
of the clutches must continue to transmit the drive at lower main pressure until the other clutch is able to
accept the input torque.
The shift elements, clutches or brakes are engaged hydraulically. The transmission fluid pressure builds up
between the cylinder and the piston, pressing the clutches together.
The purpose of these shift elements is to carry out in-load shifts with no interruption to traction.
Multi-plate clutches; forward, direct and overdrive, supply power from the engine to the planetary geartrain.
Multi-disc brakes, intermediate and low/reverse, press against the transmission housing in order to achieve a
torque reaction effect.
Major Components 2380

Multi-Plate Clutch
Clutches; O/D (E), forward (A) and direct (B) are balanced in terms of dynamic pressure. That is, their pistons
are exposed to the transmission fluid flow on both sides, in order to prevent pressure buildup in the clutch as
speed increases. This equalization process is achieved by a baffle plate and pressure-free transmission fluid
supply by a lubricating passage, through which the space between piston and baffle plate is filled with
transmission fluid.
The advantages of this dynamic pressure equalization are:
reliable clutch engagement and release in all speed ranges.

improved shift refinement.
Shift Overlap Control
The electro-hydraulic shift action is obtained by means of various valves in the TCM and main control valve
body, actuated by pressure regulators. They engage or disengage the relevant clutches or brakes at the correct
moments.
Hydraulic Systems
Fluid Pump
The torque converter is supported in the fluid pump by a needle roller bearing. The fluid pump is driven
directly from the engine by the torque converter shell and supplies transmission fluid to the transmission and
the hydraulic control unit.
The fluid pump draws in transmission fluid through a transmission fluid filter and delivers it at high pressure
to the main pressure valve in the main control valve body unit. The valve adjusts the pressure and returns
excess transmission fluid to the transmission fluid pan.
Fluid Filter
All transmission fluid that is picked up from the transmission fluid pan passes through the transmission fluid
filter. The transmission fluid filter and its accompanying seal are part of the transmission fluid path from the
pan to the transmission fluid pump.
Single Planetary Gearset
The single planetary gear O/D carrier is driven by the input shaft. The single planetary gear set consists of the
following components:
One sun gear

Four planetary gears meshing with the sun gear
One planetary carrier
One ring gear
Ravigenaux Planetary Gearset
Major Components 2381

The ravigenaux planetary gearset is splined to the output shaft and consists of the following components:
Two sun gears of different sizes

Three short planetary gear pinions meshing with the sun gears
Three long planetary gear pinions meshing with the sun gears
One ring gear
Output Shaft
The output shaft provides torque to the driveshaft and rear axle assembly. It is driven by the ring gear of the
planetary gearset.
Major Components Cutaway View
Major Components Exploded View
Major Components Cutaway View 2382


1 7902 Torque converter
2 7A103 Front pump assembly
3 - Forward clutch (A) (quantity model dependant)
4 7A398 Front planetary gearset
5 - Overdrive (O/D) clutch (E)
6 - Direct clutch (B) (quantity model dependant)
7 - Intermediate clutch (C) (quantity model dependant)
8 - Low/reverse clutch (D)
9 7G224 Rear planetary gearset
10 7005 Transmission case
11 7A100 Main control assembly
12 7G186 Transmission fluid filter
Forward Clutch (A) Plate Quantity
NOTE: The number of clutch plates are model dependant based on engine displacement.
Steel
Engine Vehicle Friction Plates Plates
4.6L Explorer, Mountaineer, Sport Trac, F-150 4 5
5.4L Expedition, Navigator, F-150 5 6
Major Components Exploded View 2383

Direct Clutch (B) Plate Quantity
Engine Vehicle Friction Plates Steel Plates

Intermediate Clutch (C) Plate Quantity
Steel
Major Components Exploded View 2384


6R80 Manual
Gear Ratios
Power is transmitted from the torque converter to the planetary gearsets through the input shaft. Clutches are
used to hold and drive certain combinations of gearsets. This results in 6 forward ratios and one reverse ratio
which are transmitted to the rear planetary ring gear (output shaft). The planetary gearsets of this transmission
provide the following ratios:
Reverse:
Front planetary gearset ratio of 1.52:1
Rear planetary gearset ratio of 2.24:1 (reverse direction)
Total ratio of 3.40:1 (reverse direction)
1st gear:
Rear planetary gearset ratio of 2.74:1
Total ratio of 4.17:1
2nd gear:
Reaanetary gearset ratio of 1.54:1
3rd gear:
Rear planetary gearset ratio of 1:1
4th gear:
Front planetary gearset provides ratios of 1:1 and 1.52:1 to different rear planetary gearset
members
5th gear:
Front planetary gearset provides ratios of 1:1 and 1.52:1 to different rear planetary gearset
members
6th gear:
Front planetary gearset ratio of 1:1
Gear Ratios 2385

Gear Ratios 2386


6R80 Manual
Range Selection
The transmission has 7 range positions: P, R, N, D, 3, 2 and 1.
Park
In the PARK position:
there is no power flow through the transmission.

the park pawl locks the output shaft to the case.
the engine can be started.
the ignition key can be removed.
&nbs
Reverse
In the REVERSE position:
the vehicle can be operated in a rearward direction, at a reduced gear ratio.

backup lamps are illuminated.
Neutral
In the NEUTRAL position:
there is no power flow through the transmission.

the output shaft is not held and is free to turn.
the engine can be started.
D Position
The D is the normal position for most forward driving.
The D position provides:
automatic shifts 1-6 and 6-1.

apply and release of the torque converter clutch.
maximum fuel economy during normal operation.
Range Selection 2387

Position 3 - 3rd Gear
This position provides:
manual 3rd gear.
Position 2 - 2nd Gear
manual 2nd gear.
Position 1 - 1st Gear
first gear operation only.

engine braking for descending steep grades.
Gear Availability
Gear Availability 2388

Gear Availability 2389


6R80 Manual
Torque Converter
The torque converter is a 4-element unit containing a 3-plate clutch. The clutch can be controlled and engaged
in any gear 2 to 6. Calibration parameters may be set to allow lockup in a higher gear only. The clutch is
applied by removing fluid pressure from one side of the plate. The torque converter transmits and multiplies
torque. The torque converter includes the following 4 elements:
Impeller assembly
Turbine assembly
Reactor assembly
Torque Converter Clutch (TCC)
Rotation of the torque converter housing and impeller set the transmission fluid in motion by driving the
impeller blades and pump.
The turbine is driven by the transmission fluid from the impeller and transmits power to the input shaft.
The reactor redirects transmission fluid flow returned from the turbin the impeller so that it rotates in the same
direction as the impeller. This action assists in torque multiplication.
The reactor has a One-Way Clutch (OWC) to hold it stationary during torque multiplication and allows it to
rotate at higher vehicle speeds.
Torque Converter Operation
Item Description
1 Torque Converter Clutch (TCC)
2 Reactor
3 Turbine
4 Impeller and cover assembly
5 One-Way Clutch (OWC)
6 Fluid motion
7 Input shaft rotation
Torque Converter 2390

8 Input shaft
9 Engine rotation
The TCC has a cover assembly with a 3-plate clutch and a turbine and damper assembly that connects to the
transmission input shaft.
The TCC connects the cover to the turbine when the TCC is applied.
During TCC release, transmission fluid flows through the torque converter in one direction to release the
3-plate clutch.
During TCC apply, transmission fluid flows through the torque converter in the opposite direction to apply the
3-plate clutch.
The TCC operates in 3 stages:
Full release
Controlled modulation
Full apply
The Transmission Control Module (TCM) controls TCC operation using the TCC solenoid. TCC solenoid
operation provides the modulation of hydraulic pressure to change the position of the bypass clutch control
regulator valve. The valve changes the pressure and direction of transmission fluid flow in the torque
converter. The TCC may be applied in forward gears, 2 to 6.
Torque Converter Exploded View

1 7902 Torque converter assembly
2 - Cover assembly with 3-plate clutch
3 - 3-plate clutch
4 - Turbine and damper assembly
5 - Needle bearing assemblies
6 - Reactor assembly with One-Way Clutch (OWC)
7 - Impeller assembly
Torque Converter Operation 2391

Torque Converter Exploded View 2392


6R80 Manual
Shift Patterns
Downshifts
Under certain conditions, the transmission will downshift automatically to a lower gear range (without
moving the range selector lever). There are 3 categories of automatic downshifts:
Coastdown
Torque demand
Forced or kickdown shifts
Coastdown
The coastdown downshift occurs when the vehicle is coasting down to a stop.
Torque Demand
The torque demand downshift occurs (automatically) during part throttle acceleration when the demand for
torque is greater than the engine can provide at that gear ratio.
Kickdown
For maximum acceleration, the driver can force a downshift by pressing the accelerator pedal to the floor. A
forced downshift into a lower gear is possible below calibrated speeds. Specifications for downshift speeds are
subject to variations due to tire size, engine and transmission calibration requirements.
Shift Patterns 2393

Shift Patterns 2394


6R80 Manual
Mechanical Components and Functions
Planetary Gearset
This transmission has 2 planetary gearsets (front and rear) to provide operation in reverse and 6 forward
speeds.
The front planetary gearset is a single planetary gearset and has the following components:
Front planetary No. 1 sun gear

Front planetary carrier
Front planetary ring gear (part of the input shaft assembly)
The input shaft rotates the front ring gear as a driving member. The front sun gear is connected to the fluid
pump and is held stationary. The front ring gear rotates the front planetary carrier assembly with a reduction
ratio of 1.52:1
The front planetary carrier assembly is the only output member of the front planetary gearset in reverse, 1st
gear, 2nd gear and 3rd gear. The front planetary gearseovides a 1.52:1 gear ratio to the rear planetary gearset.
In 4th gear and 5th gear, both the front ring gear and front planetary carrier assembly are output members of
the front planetary gearset. The front planetary gearset provides both a 1:1 and 1.52:1 gear ratio to different
members of the rear planetary gearset.
In 6th gear, the front ring gear is the only output member of the front planetary gearset. The front planetary
gearset provides a 1:1 gear ratio to the rear planetary gearset.
The rear planetary gearset is a ravigenaux planetary gearset and has the following components:
Rear planetary No. 2 sun gear

Rear planetary No. 3 sun gear
Rear planetary carrier assembly (2 sets of pinion gears)
Rear planetary ring gear assembly
Powerflow through the rear planetary gearset is as follows:
In reverse, rear sun gear No. 2 is driven, the rear planetary carrier is held and the ring gear is the
output (2.24:1 with reverse direction)
In 1st gear, sun gear No. 3 is driven, the rear planetary carrier is held and the ring gear is the output
(2.74:1)
In 2nd gear, sun gear No. 3 is driven, sun gear No. 2 is held and the ring gear is the output (1.54:1)
In 3rd gear, sun gear No. 3 and sun gear No. 2 are driven and the ring gear is the output (1:1)
In 4th gear, sun gear No. 3 and the rear planetary carrier are driven and the ring gear is the output
(1.14:1)
In 5th gear, sun gear No. 2 and the rear planetary carrier are driven and the ring gear is the output
(0.87:1)
In 6th gear, the rear planetary carrier is driven, sun gear No. 2 is held and the ring gear is the output
(0.69:1)
Mechanical Components and Functions 2395

Planetary Gearset Cutaway View
Planetary Gearset Exploded View

1 7D063 Front planetary No. 1 sun gear
2 7A398 Front planetary carrier
3 7F207 Front planetary ring gear (part of input shaft assembly)
4 7D063 Rear planetary No. 2 sun gear
6 7D006 Rear planetary carrier
7 7A153 Rear planetary ring gear
8 7060 Output shaft
Forward Clutch (A)
The forward clutch (A) connects the front planetary carrier to the rear No. 3 sun gear. This provides a
reduction gear ratio of 1.52:1 from the input shaft to rear sun gear No. 3. The forward (A) is applied in 1st,
2nd, 3rd and 4th gears.
Regulated hydraulic pressure from the regulator valve in the valve body pushes the forward (A) clutch piston
against the forward (A) clutch pack to apply the clutch. The front planetary carrier and the rear No. 3 sun gear
are connected as a result of the clutch being applied.
Planetary Gearset Cutaway View 2396

Forward Clutch (A) Cutaway View
Forward Clutch (A) Exploded View

1 7A360 Forward clutch (A) cylinder
2 7A262 Forward clutch piston
3 7A480 Forward clutch piston retaining spring
4 7H360 Forward clutch balance piston
5 7E085 Forward clutch wave spring
6 7B164 Forward clutch assembly (quantity model dependant)
7 7B066 Forward clutch pressure plate
8 7D483 Forward clutch snap ring
9 7A398 Front planetary carrier assembly
10 7B067 Rear planetary No. 3 sun gear hub and shaft assembly
Steel
Forward Clutch (A) Cutaway View 2397

Direct Clutch (B)
The direct clutch (B) connects the front planetary carrier to the rear No. 2 sun gear. This provides a reduction
gear ratio of 1.52:1 from the input shaft to rear sun gear No. 2. The direct clutch (B) is applied in reverse, 3rd
and 5th gears.
Regulated hydraulic pressure from the regulator valve in the valve body pushes the direct clutch (B) piston
against the direct clutch (B) pack to apply the clutch. The front planetary carrier and the rear No. 2 sun gear
are connected as a result of the clutch being applied.
Direct Clutch (B) Cutaway View
Direct Clutch (B) Exploded View

1 7A360 Forward clutch (A) cylinder
2 7H360 Forward clutch balance piston
4 7F236 Direct clutch (B) hub
5 7C122 Direct clutch cylinder retaining ring
6 7D483 Direct clutch pressure plate retaining ring
Forward Clutch (A) Exploded View 2398

7 7B066 Direct clutch pressure plate

8 - Direct clutch assembly (quantity model dependant)
9 7E085 Direct clutch cushion plate
10 7H359 Direct clutch balance piston
11 7B488 Direct clutch piston return spring
12 7A262 Direct clutch piston
13 7F360 Direct clutch cylinder
14 7D063 Rear planetary sun gear No. 2
Direct Ctch (B) Plate Quantity
Steel
Intermediate Clutch (C)
The intermediate clutch (C) holds the rear planetary No. 2 sun gear stationary to the transmission case. The
intermediate clutch (C) is applied in 2nd and 6th gears.
Regulated hydraulic pressure from the regulator valve in the valve body pushes the intermediate clutch (C)
piston against the intermediate clutch (C) pack to apply the clutch.
Intermediate Clutch (C) Cutaway View
Direct Clutch (B) Exploded View 2399

Intermediate Clutch (C) Exploded View

1 7F360 Direct clutch (B) cylinder
2 7D483 Center support retaining ring
3 7D483 Intermediate clutch (C) pressure plate retaining ring
4 7B066 Intermediate clutch pressure plate
5 7B164 Intermediate clutch assembly (quantity model
dependant)
6 7E085 Intermediate clutch plate spring
7 7A480 Intermediate clutch piston return spring
8 7E005 Intermediate clutch piston
9 7A130 Center support assembly
10 7D063 Rear planetary sun gear No. 2
11 7005 Transmission case assembly
Steel
Low/Reverse Clutch (D)
The low/reverse clutch (D) holds the rear planetary carrier stationary to the transmission case. The low/reverse
clutch (D) is applied in park, reverse, neutral and 1st gear.
Regulated hydraulic pressure from the regulator valve in the valve body pushes the low/reverse clutch (D)
piston against the low/reverse clutch (D) pack to apply the clutch.
Low/Reverse Clutch (D) Cutaway View
Intermediate Clutch (C) Exploded View 2400

Low/Reverse Clutch (D) Exploded View

1 7D483 Low/reverse clutch piston retaining ring
2 7A130 Center support assembly
3 7A262 Low/reverse clutch (D) piston
4 7B070 Low/reverse clutch piston return spring
5 7E085 Low/reverse clutch disc cushion plate
6 - Low/reverse clutch assembly
7 7B442 Low/reverse clutch pressure plate
8 7D006 Rear planetary carrier assembly
9 7005 Transmission case assembly
Overdrive (O/D) Clutch (E)
The O/D clutch (E) connects the input shaft with the rear planetary carrier. The O/D clutch (E) is applied in
4th, 5th and 6th gears.
Regulated hydraulic pressure from the regulator valve in the valve body pushes the O/D clutch (E) piston
against the O/D clutch (E) pack to apply the clutch.
Overdrive (O/D) Clutch (E) Cutaway View
Low/Reverse Clutch (D) Cutaway View 2401

Overdrive (O/D) Clutch (E) Exploded View

1 7F207 Input shaft assembly
2 7A262 Overdrive (O/D) clutch (E) piston
3 7B070 O/D clutch (E) piston spring
4 7H360 O/D clutch (E) balance piston
5 7B164 O/D clutch (E) assembly
6 7B066 O/D clutch (E) pressure plate
7 7F351 Intermediate shaft
External Sealing
The pump assembly has a lip-type seal for the torque converter impeller hub. The pump assembly uses a large
O-ring to seal the transmission case. The pump bolts also seal the pump to the transmission case.
The manual control shaft has a lip seal for its bore in the transmission case.
The transmission fluid pan uses a reusable gasket.
The Four-Wheel Drive (4WD) applications use a lip-type seal that seals the transmission case to the output
shaft flange.
The Rear Wheel Drive (RWD) applications use a lip-type seal that seals the transmission case to the output
shaft flange.
Overdrive (O/D) Clutch (E) Cutaway View 2402

The transmission case housing plug provides access to the park pawl shaft. The plug has a seal that is serviced
as an assembly with the plug.
The bulkhead connector sleeve has a seal for the transmission case bore. The seal is serviced as an assembly
with the bulkhead connector sleeve.
The plug for the fluid level indicator uses an O-ring seal.
External Sealing (Gaskets, O-rings and Seals)

1 7902 Torque converter
2 7A248 Torque converter hub seal
3 7N134 Pump assembly bolt
4 - Pump body (part of 7A103)
5 7A248 Pump assembly inner seal
6 7A103 Pump assembly
7 7A248
9 7B498 Manual control lever shaft seal
10 7A256 Manual control lever
11 W708455 Manual control lever nut
12 7A191 Transmission fluid pan gasket
Overdrive (O/D) Clutch (E) Exploded View 2403

13 7A194 Transmission fluid pan

14 7052 Four-Wheel Drive (4WD) output shaft seal
15 7045 Rear Wheel Drive (RWD) output shaft flange
nut
16 7089 RWD output shaft flange
17 7052 Extension housing flange seal
18 7052 RWD output shaft flange seal
19 7H398 Transmission case plug (park pawl shaft
access)
20 7G276 Transmission bulkhead connector sleeve
21 7A010 Transmission fluid level indicator
22 - Transmission fluid level indicator plug seal
(part of 7A010)
23 - Transmission fluid level indicator plug (part
of 7A010)
Bushings, Bearings and Thrust Washer Locations
This transmission supports the rotating compon of the transmission with bushings, bearings and thrust
washers.
The pump assembly support thrust washer controls the amount of end play for components between the pump
assembly and the center support (forward/Overdrive (O/D) clutch assembly, direct clutch cylinder).
The T8 thrust bearing outer race controls the amount of end play for components between the center support
and the rear of the transmission case (rear planetary gearset assembly, output shaft assembly).
Part
1 7D014 Front pump support thrust washer
2 7H375 T1 thrust bearing
3 7C096 T3 thrust bearing
4 7F373 T6 thrust bearing
5 7D235 T8 thrust bearing outer race
6 7D234 T8 thrust bearing
7 7G178 T10 thrust bearing
External Sealing (Gaskets, O-rings and Seals) 2404

8 7A415 Output shaft bearing assembly

9 - Front oil pump bearing assembly (part of pump
assembly, 7A103)
10 7L495 T2 bearing
11 7H375 T4 bearing
12 7C096 T5 bearing
13 7C041 T7 bearing
/td>
14 7D234 T9 bearing
15 - T9 thrust bearing outer race
16 7B368 T11 bearing
17 7B368 T12 bearing
Lubrication
This transmission provides lubrication for rotating mechanical components through one main hydraulic
circuit. The general flow of lubrication moves from the front of the transmission, through the input and
intermediate shafts, to the rear of the transmission.
Transmission fluid from the pump assembly and the torque converter exit the transmission case to go to the
transmission fluid cooler through the bottom transmission fluid cooler tube and returns to the transmission
through the top transmission fluid cooler tube.
With lower transmission fluid temperatures, the thermal bypass valve in the transmission case will bypass the
transmission fluid cooler tubes and redirect the fluid to the lubrication circuit. As transmission fluid
temperature increases, the thermal bypass valve directs the fluid to the transmission fluid cooler.
Transmission fluid from the transmission fluid cooler or the thermal bypass valve enters the main lubrication
circuit from the top transmission fluid cooler tube port.
Transmission fluid in the lubrication circuit flows to each of the balance pistons for the forward (A), direct (B)
and Overdrive (O/D) (E) clutches. The balance pistons prevent unwanted clutch application when the clutch
cylinder rotates at high speeds and hydraulic controls have released the clutch.
Lubrication Passages
Lubrication Passages 2405

Item Description
1 Transmission fluid cooler return (inlet from the transmission fluid cooler)
2 Transmission fluid cooler pressure (outlet to the transmission fluid cooler)
Park
The park gear is part of the output shaft assembly. The park gear has lugs on its OD surface that the park pawl
engages with to lock the output shaft.
The park lock prevents the vehicle wheels from rotating by allowing the output shaft to be held stationary by
the transmission case through the park pawl. When the park pawl is engaged in the park gear, the output shaft
is held stationary.
When the manual control lever is rotated to the PARK position, the park lock works as follows:
The detent assembly (connected to the manual control shaft) rotates and pushes the park pawl actuator
rod into the park pawl. The actuator rod is spring loaded.
The actuator rod is guided into the park pawl by the park pawl abutment.
When the park pawl actuator rod is pushed into the park pawl, the park pawl pivots into the park gear
and engages with the lugs.
The park pawl holds the output shaft to the transmission case.


2 7060 Park gear (output shaft)
3 7A441 Park pawl
4 7D070 Park pawl return spring
5 7D010 Park pawl pin
6 7H398 Plug - park pawl pin
7 7G101 Park pawl actuator rod
8 7E332 Manual control lever detent spring
9 7A115 Manual valve detent assembly
10 7C493 Manual shaft
12 7G101 Park pawl abutment



6R80 Manual
Hydraulic System
Pump Assembly and Transmission Fluid Filter
This transmission has a gear type pump that supplies transmission fluid pressure to the hydraulic system.
The inner (drive) gear is turned by the torque converter hub.
The transmission fluid pump has the following parts:
Pump body, with inner (drive) and outer (driven) gears

Centering plate
Intermediate plate
Stator shaft
The transmission fluid pump draws transmission fluid from the sump area, formed by the transmission fluid
pan, through the transmission fluid filter, which is installed into the intermediate plate portion of the pump
assembly and sealed by a rubber seal. A magnet attached to the transmission fluid pan collects any metallic
material in the transmission fluid.
Pump Assembly and Transmission Fluilter Components

1 7A103 Transmission fluid pump assembly
2 7A098 Transmission fluid filter
3 - Transmission fluid filter seal (part of 7A098)
4 - Transmission fluid pump body (part of 7A103)
5 - Inner (drive) gear (part of 7A103)
6 - Outer (driven) gear (part of 7A103)
7 - Centering plate (part of 7A103)
8 - Intermediate plate (part of 7A103)
9 - Filter suction port
Hydraulic System 2409

10 - Stator shaft (part of 7A103)
Transmission Fluid Level Indicator
A removable dipstick-type fluid level indicator is located on the right front area of the transmission case. It is
held in by an external fluid fill plug. The transmission fluid level indicator is removed with the transmission
fluid fill plug. The transmission fluid level indicator is removed from the fill plug to check the transmission
fluid level.
The transmission fluid level is correctly checked when the transmission is at normal operating temp5C
(175F-185F), and the vehicle is on a level surface.
The transmission can have 2 types of transmission fluid level indicators, the original or the replacement. The
original transmission fluid level indicator has a single crosshatch area for the fluid level. The replacement has
2 areas for the fluid level, a crosshatched (labeled A) area and a dotted (labeled B) area. Use the crosshatched
area when checking the transmission fluid level. The correct transmission fluid level is at the upper level of
the crosshatch marks on the transmission fluid level indicator.
Transmission Fluid Level Indicator

1 - Transmission fluid fill plug
2 7A010 Transmission fluid level indicator
3 - Original transmission fluid level indicator FULL line
4 - Replacement transmission fluid level indicator FULL
line
Main Control (Mechatronic) Assembly
The hydraulic system of this transmission includes the fluid pump, a main control, or mechatronic assembly
and fluid passages in the transmission case and center support to apply the clutches.
The main control assembly has an upper valve body assembly, a separator plate and a lower valve body
assembly. The lower valve body assembly has 7 solenoids to control the vahe main control.
The Transmission Control Module (TCM) is part of the mechatronic assembly and is bolted to it. The Turbine
Shaft Speed (TSS) sensor, Output Shaft Speed (OSS) sensor, Transmission Range (TR) sensor and the
Transmission Fluid Temperature (TFT) sensor are all part of the TCM .
Pump Assembly and Transmission Fluilter Components 2410

Mechatronic Assembly
Mechatronic Assembly 2411


1 - Transmission Control Module (TCM) (part of 7A100)
2 - Transmission control valve body (upper)
3 7E195 Transmission control valve check ball (8 required)
4 7Z490 Transmission control valve body separator plate
5 - Transmission control valve body (lower)
6 - Transmission control valve assembly
7 7H187 Transmission control filter assembly
8 7B155 Transmission fluid filter
9 - Transmission solenoid damper valve assembly
10 7G383 Shift Solenoid A (SSA) Variable Force Solenoid
(VFS)
11 7G383 Shift Solenoid B (SSB) VFS
12 7G383 Shift Solenoid C (SSC) VFS
13 7G383 Line Pressure Control (LPC) solenoid VFS
14 7G383 Shift Solenoid D (SSD) VFS
15 7G484 Shift Solenoid E (F solenoid
16 7G383 Torque Converter Clutch (TCC) solenoid VFS
17 - Forward (A) clutch latch valve assembly
18 - Direct (B) clutch latch valve assembly
19 - Solenoid regulator valve
20 - Low/reverse (D1) clutch latch valve assembly
21 - Drive enable valve
22 - Solenoid multiplex valve
23 - Forward (A) clutch regulator valve assembly
24 - Overdrive (O/D) (E) clutch regulator valve assembly
25 - O/D (E) clutch latch valve assembly
26 - Bypass clutch control regulator valve assembly
27 - Main regulator valve assembly
28 - Converter release regulator valve assembly
29 - Lubrication control valve assembly
30 - Manual valve assembly
31 - Low/reverse (D2) clutch latch valve assembly
32 - Low/reverse (D2) clutch regulator valve assembly
33 - Direct (B) clutc
34 - Low/reverse (D1) clutch regulator valve assembly

35 - Intermediate (C) clutch regulator valve


6R80 Manual
Hydraulic Circuits
Hydraulic Circuit Identification and Function
Hydraulic Circuit Identification Chart
Circuit
Name Description
BREVA BREV5 pressure from the drive enable valve to the clutch A regulator valve.
BREV5 BREV 5F pressure from the clutch A latch valve to the drive enable valve and the No. 2
shuttle ball.
BREV 5F Regulated line pressure from the CL B circuit directed to the A clutch latch valve by the B
clutch latch valve.
BREV5/SS1 BREV5 or SS1 pressure from the No. 2 shuttle ball to the solenoid multiplex valve.
CAPLY Apply circuit to the torque converter, also the return circuit during Torque Converter Clutch
(TCC) release.
CAPLY EX TCC release pressure from the bypass clutch control regulator valve to the converter release
regulator valve.
CAPLY F Line pressure from the PUMP circuit directed to the bypass clutch control regulator valve by
the main regulator valve.
CL A Regulated line pressure from the clutch A regulator valve to the clutch A latch valve and the
forward (A) clutch to apply the clutch.
CLA FB Regulated line pressure from the clutch A latch valve that feeds back to the clutch A regulator
valve.
CL B Regulated line pressure from the clutch B regulator valve to the clutch B latch valve and the
direct (B) clutch to apply the clutch.
CLB FB Regulated line pressure from the clutch B latch valve that feeds back to the clutch B regulator
valve.
CL C Regulated line pressure from the clutch C regulator valve to the intermediate (C) clutch to
apply the clutch.
CL D1
Hydraulic Circuits 2414

Regulated line pressure from the clutch D1 regulator valve to the clutch D1 latch valve and the
low/reverse (D) clutch to apply the clutch.
CL D1 FB Regulated line pressure from the clutch D1 latch valve that feeds back to the clutch D1
regulator valve.
CL D2 Regulated line pressure from the clutch D2 regulator valve to the low/reverse (D) clutch to
apply the clutch.
CL DC Regulated solenoid output pressure from Shift Solenoid D (SSD) directed by the solenoid
multiplex valve to the D1 and D2 regulator and latch valves to apply the low/reverse (D)
clutch.
CLE Regulated line pressure from the clutch E regulator valve to the clutch E latch valve and the
Overdrive (O/D) (E) clutch to apply the clutch.
CLEC Regulated solenoid output pressure from the CLEC F circuit directed by the drive enable valve
to the clutch E regulator and latch valves to apply the clutch.
CLEC F Regulated solenoid output pressure from the VFS4 circuit directed to the drive enable valve by
the solenoid multiplex valve to move the clutch E regulator and latch valves to apply the O/D
(E) clutch.
CLE FB Regulated line pressure from the clutch E latch valve that feeds back to the clutch E regulator
valve.
CL EXH Line pressure regulated to approximately 21 kPa (3 psi) by the D2 latch valve that supplies
exhaust pressure to the A, B, C, D1 and E clutch when the clutches are released.
COOLF Pressure from the lubrication control valve to the oil cooler or the thermal bypass valve that
feeds the lubrication circuit.
CREL Pressure supplied to the torque converter by the converter release regulator valve to release the
TCC .
CREL F Line pressure from the main regulator valve that supplies the converter release regulator valve
and the lubrication control valve.
DBACK CAPLY EX pressure directed to the drain back valve by the converter release regulator valve.
DRIVE Line pressure directed by the manual valve to the A, C and E clutch regulator valves and the
No. 1 shuttle ball.
LUBE Transmission lubrication circuit supplied by the COOLF circuit after the fluid circulates the
transmission fluid cooler or is returned by the cooler bypass valve.
PUMP Line pressure supplied by the pump to the manual valve, solenoid pressure regulator valve,
main regulator valve, clutch D1 regulator valve, clutch D2 regulator valve and clutch D2 latch
valve.
REV Line pressure from the manual valve to the No. 1 shuttle ball and the solenoid multiplex valve.
REV/DRIVE REV or DRIVE pressure from the No. 1 shuttle ball to the clutch B regulator valve.
SCHG Line pressure from the main regulator valve to the pump suction port.
SREG Line pressure from the solenoid regulator valve that supplies pressure to the 7 solenoids (Shift
Solenoid A (SSA), Shift Solenoid B (SSB), Shift Solenoid C (SSC), SSD , Shift Solenoid E
(SSE), TCC solenoid and Line Pressure Control (LPC) solenoid).
SS1 Solenoid output pressure from SSE to the drive enable valve and to shuttle ball No. 2. to direct
SSD output pressure to clutch E regulator and latch valves to apply the O/D (E) clutch.
VFS1 Solenoid output pressure from SSA to the A clutch regulator and latch valve to apply the
forward (A) clutch.
VFS2 Solenoid output pressure from SSB to the B clutch regulator and latch valve to apply the direct
(B) clutch and is also routed to the D1 latch valve.
VFS2D SSB output pressure from the VFS2 circuit directed to the clutch B regulator valve by the D1
latch valve.
Hydraulic Circuits 2415

VFS3 Solenoid output pressure from SSC to the C clutch regulator valve to apply the intermediate
(C) clutch and is also routed to the clutch E latch valve.
VFS3E SSC output pressure from the VFS3 circuit directed to the clutch C regulator valve by the
clutch E latch valve.
VFS4 Solenoid output pressure from SSD to the solenoid multiplex valve to apply either the D or E
clutch.
VFS5 Solenoid output pressure from the LPC solenoid to the main regulator valve to control line
pressure.
VFS6 Solenoid output pressure from the TCC solenoid to the bypass clutch control regulator valve
and the converter release regulator valve to control the TCC .
Main Control Hydraulic Passage Identification
Main Control Hydraulic Passage Identification 2416

Line Pressure Hydraulic Circuits
The Transmission Control Module (TCM) controls line pressure with the Line Pressure Control (LPC)
solenoid. Varying pressure from the LPC solenoid effects shift feel while allowing sufficient pressure for
clutch application.
When the engine is running, the pump supplies pressure to the main regulator valve through the PUMP
circuit. The position of the main regulator valve controls line pressure (in the PUMP circuit). Pressure from
the LPC solenoid through the VFS5 circuit controls the position of the main regulator valve.
The main regulator valve varies pressure in the SCHG circuit. The higher the pressure in the SCHG circuit,
the lower the line pressure (PUMP circuit) is. As SCHG pressure decreases, line pressure (PUMP circuit)
increases.

Lubrication Hydraulic Circuits
The main regulator valve supplies pressure to the lubrication control valve through the CREL F circuit. When
the Torque Converter Clutch (TCC) is applied, the lubrication control valve supplies the transmission
lubrication through the COOLF circuit to the LUBE circuit.
When the TCC is released, return fluid from the torque converter is supplied to the LUBE circuit through the
CAPLY, CAPLY EX and DBACK circuits.
Pressure in the LUBE circuit either circulates through the thermal bypass valve when Transmission Fluid
Temperature (TFT) is below operating temperature or through the transmission fluid cooler when the
transmission fluid is at or above operating temperature. Return fluid from the thermal bypass valve or the
transmission fluid cooler enters the input shaft through the pump assembly and flows through passages in the
input shaft, intermediate shaft and output shaft to provide lubrication for the transmission.
Torque Converter Hydraulic Circuits
When the TCC is released, line pressure is supplied to the converter release regulator valve from the
lubrication control valve through the CREL F circuit. The converter release regulator valve supplies pressure
to the torque converter through the CREL circuit to release the torque converter.
CREL pressure exits the torque converter through the CAPLY circuit and goes to the bypass clutch control
regulator valve. The bypass clutch control regulator valve directs the fluid back to the converter release
regulator valve through the CAPLY EX circuit. The converter release regulator valve directs the fluid to the

DBACK circuit where it supplies lubrication in the LUBE circuit.
When the TCC is applied, the TCC solenoid applies hydraulic pressure to the bypass clutch control regulator
valve and the converter release regulator valve through the VFS6 circuit to position the valves to apply the
TCC .
Line pressure is supplied to the bypass clutch control regulator valve from the main regulator valve. The
bypass clutch control regulator valve directs regulated line pressure to the TCC through the CAPLY circuit to
apply the TCC .
CAPLY pressure exits the torque converter through the CREL circuit and goes to the converter release
regulator valve.
For torque converter description and function, refer to Torque Converter Contamination Inspection in this
section.

Solenoid Hydraulic Circuits
LINE pressure from the pump is directed to the individual shift, TCC and LPC solenoids by the solenoid
regulator valve through the SREG circuit. The solenoids, controlled by the TCM , direct full or regulated
SREG pressure to the valves that they control.
For electrical operation of the solenoids, refer to Transmission Electronic Control System in this section.
The LPC solenoid sends varying pressure to the main regulator valve to control line pressure.
In the PARK and NEUTRAL position, the TCM supplies low amperage to Shift Solenoid D (SSD) to apply
high-regulated pressure to the solenoid multiplex valve which directs the pressure to the D1 and D2 regulator
and latch valves to apply the low/reverse clutch (D).
In the REVERSE position, the TCM supplies low amperage to Shift Solenoid B (SSB) to apply high-regulated
pressure to the clutch B regulator and latch valves to apply the direct clutch (B). The TCM also supplies low
amperage to SSD to apply high-regulated pressure to the solenoid multiplex valve which directs the pressure
to the D1 and D2 regulator and latch valves to apply the low/reverse clutch (D).

In 1st gear, the TCM supplies high amperage to Shift Solenoid A (SSA) to apply high-regulated pressure to
the clutch A regulator and latch valves to apply the forward clutch (A). The TCM also supplies low amperage
to SSD to apply high-regulated pressure to the solenoid multiplex valve which directs the pressure to the D1
and D2 regulator and latch valves to apply the low/reverse clutch (D).
In 2nd gear, the TCM supplies high amperage to SSA to apply high-regulated pressure to the clutch A
regulator and latch valves to apply the forward clutch (A). The TCM also supplies high amperage to Shift
Solenoid C (SSC) to apply high-regulated pressure to the clutch C regulator valve to apply the intermediate
clutch (C).
In 3rd gear, the TCM supplies high amperage to SSA to apply high-regulated pressure to the clutch A
regulator and latch valves to apply the forward clutch (A). The TCM also supplies low amperage to Shift

Solenoid B (SSB) to apply high-regulated pressure to the clutch B regulator and latch valves to apply the
direct clutch (B).
In 4th gear, the TCM supplies high amperage to SSA to apply high-regulated pressure to the clutch A
regulator and latch valves to apply the forward clutch (A). The TCM also supplies low amperage to SSD to
apply high-regulated pressure to the solenoid multiplex valve which directs the pressure to the clutch E
regulator and latch valves to apply the Overdrive (O/D) clutch (E). The TCM turns on Shift Solenoid E (SSE)
to apply pressure to the solenoid multiplex valve and the drive enable valve to direct SSD pressure to the
clutch E regulator and latch valves.
In 5th gear, the TCM supplies low amperage to SSD to apply high-regulated pressure to the solenoid
multiplex valve which directs the pressure to the clutch E regulator and latch valves to apply the O/D clutch
(E). The TCM turns on SSE to apply pressure to the solenoid multiplex valve and the drive enable valve to
direct SSD pressure to the clutch E regulator and latch valves. The TCM also supplies low amperage to SSB
to apply high-regulated pressure to the clutch B regulator and latch valves to apply the direct clutch (B).

In 6th gear, the TCM supplies low amperage to SSD to apply high-regulated pressure to the solenoid
multiplex valve which directs the pressure to the clutch E regulator and latch valves to apply the O/D clutch
(E). The TCM turns on SSE to apply pressure to the solenoid multiplex valve and the drive enable valve to
direct SSD pressure to the clutch E regulator and latch valves. The TCM also supplies high amperage to SSC
to apply high-regulated pressure to the clutch C regulator valve to apply the intermediate clutch (C). To apply
the TCC , the TCM supplies high amperage to the TCC solenoid to apply high-regulated pressure to the
converter release regulator valve and the bypass clutch control regulator valve to apply the TCC .
In 3rd gear fail safe, all solenoids are off. SSB , in the off position, applies high pressure to the clutch B
regulator and latch valves to apply the direct clutch (B). The forward clutch (A) is hydraulically applied in 3rd
gear fail safe. The LPC solenoid provides maximum solenoid pressure to the main regulator valve for
maximum line pressure. Also, SSD is on which applies high pressure to the solenoid multiplex valve which is
directed to the drive enable valve where it is blocked.

Forward Clutch (A) Hydraulic Circuits
To apply the forward clutch (A), the manual valve must be in the DRIVE, 3, 2 or 1 position to provide line
pressure to the clutch A regulator valve through the DRIVE circuit.
For the forward clutch (A) to apply, SSA provides regulated solenoid pressure from the SREG circuit to the
clutch A regulator and latch valves through the VFS1 circuit to position the valves to apply the forward clutch
(A). As the forward clutch is applied, SSA increases pressure to the clutch A regulator and latch valves.
The clutch A regulator valve provides regulated line pressure to the CL A circuit to apply the forward clutch
(A).
The forward clutch (A) is released when the manual valve is in the NEUTRAL, REVERSE or PARK position
or the when the manual valve is in the DRIVE position with the transmission in 5th or 6th gear.
SSA lowers pressure to the clutch A regulator and latch valve to position the valves to lower the regulated line
pressure in the CL A circuit to release the clutch.
When the forward clutch (A) is released, the clutch A regulator valve directs exhaust circuit pressure from the
CL EXH circuit to the CL A circuit to fill the circuit and the forward clutch (A) with fluid at low pressure,
approximately 21 kPa (3 psi).

Direct Clutch (B) Hydraulic Circuits
To apply the direct clutch (B), the manual valve can be in the REVERSE, DRIVE, 3, 2 or 1 position to
provide line pressure to the clutch B regulator valve through the REV/DRIVE circuit.
For the direct clutch (B) to apply in reverse, SSB provides regulated solenoid pressure from the SREG circuit
to the clutch B regulator and latch valves through the VFS2 circuit to position the valves to apply the direct
clutch (B). As the direct clutch is applied, SSB increases pressure to the clutch B regulator and latch valves.
The clutch B regulator valve provides regulated line pressure to the CL B circuit to apply the direct clutch (B).
When the direct clutch (B) is applied in 3rd and 5th gear, regulated solenoid pressure from the D1 latch valve
is supplied to the clutch B regulator valve through the VFS2D circuit and opposes pressure from the VFS2
circuit for clutch B valve positioning.

The direct clutch (B) is released when the manual valve is in the PARK or NEUTRAL position or when the
manual valve is in the DRIVE position with the transmission in 1st, 2nd, 4th or 6th gear.
In NEUTRAL or PARK, the manual valve does not supply line pressure to the clutch B regulator valve. SSB
lowers pressure to the clutch B regulator and latch valve to position the valves to lower the regulated line
pressure in the CL B circuit to release the clutch.
In 1st, 2nd, 4th or 6th gear, the manual valve supplies line pressure to the clutch B regulator valve. SSB
lowers pressure to the clutch B regulator and latch valve to position the valves to lower the regulated line
pressure in the CL B circuit to release the clutch.
When the direct clutch (B) is released in 1st, 2nd, 4th or 6th gear, the clutch (B) regulator valve directs

exhaust circuit pressure from the CL EXH circuit to the CL B circuit to fill the circuit and the direct clutch (B)
with fluid at low pressure, approximately 21 kPa (3 psi).
Intermediate Clutch (C) Hydraulic Circuits
To apply the intermediate clutch (C), the manual valve can be in the DRIVE, 3, 2 or 1 position to provide line
pressure to the clutch C regulator valve through the DRIVE circuit.
SSC provides regulated solenoid pressure from the SREG circuit to the clutch C regulator valve through the
VFS3 circuit to position the valve to apply the intermediate clutch (C). As the intermediate clutch (C) is
applied, SSC increases pressure to the clutch C regulator valve.
The clutch C regulator valve provides regulated line pressure to the CL C circuit to apply the intermediate
clutch (C).
Regulated solenoid pressure from the clutch E latch valve is supplied to the clutch C regulator valve through
the VFS3E circuit and opposes VFS3 pressure for clutch C regulator valve positioning in 6th gear only.

To release the intermediate clutch (C) when the manual valve is in the DRIVE, 3, 2 or 1 position SSC lowers
pressure to the clutch C regulator valve to position the valve to lower the regulated line pressure in the CL C
circuit to release the clutch.
When the intermediate clutch (C) is released, the clutch C regulator valve directs exhaust circuit pressure from
the CL EXH circuit to the CL C circuit to fill the CL C circuit and the intermediate clutch (C) with fluid at
low pressure, approximately 21 kPa (3 psi).
In PARK, REVERSE or NEUTRAL, the manual valve does not supply line pressure to the clutch C regulator
valve.
Low/Reverse Clutch (D) Hydraulic Circuits
To apply the low/reverse clutch (D), the manual valve can be in any position. Line pressure is supplied to the
D1 and D2 regulator and latch valves by the pump through the PUMP circuit.
SSD provides regulated solenoid pressure from the SREG circuit to the solenoid multiplex valve through the
VFS4 circuit where it is directed to the D1 and D2 regulator and latch valves through the CL DC circuit to
position the valves to apply the low/reverse clutch (D). As the low/reverse clutch (D) is applied, SSD
increases pressure to the D1 and D2 clutch regulator and latch valves.
The clutch D1 and D2 regulator valves provide regulated line pressure from the PUMP circuit to the CL D1
and CL D2 circuits to apply the low/reverse clutch (D).

To release the low/reverse clutch (D), the manual valve can be in the DRIVE, 3 or 2 position. SSD lowers
pressure to the VFS4 circuit which lowers pressure in the CL DC circuit to position the D1 and D2 regulator
and latch valves to lower pressure in the CL D1 and CL D2 circuits and release the low/reverse clutch (D).
When the low/reverse clutch (D) is released, the clutch D2 latch valve directs line pressure regulated to
approximately 21 kPa (3 psi) to the CL EXH circuit which fills the volume of the unused clutches and
circuits.
When the low/reverse clutch (D) is released, the CL EXH circuit supplies the D1 regulator valve which fills
the CL D1 circuit and the low/reverse (D) clutch.

Overdrive (O/D) Clutch (E) Hydraulic Circuits
To apply the O/D clutch (E), the manual valve must be in the DRIVE position. Line pressure is supplied to the
clutch E regulator valve.
SSD provides regulated solenoid pressure from the SREG circuit to the solenoid multiplex valve through the
VFS4 circuit. SSE supplies pressure to the solenoid multiplex valve and the drive enable valve to position the
valves to direct pressure from the VFS4 circuit to the CLEC F and CLEC circuits to position the clutch E
regulator and latch valves to apply the O/D clutch (E). As the O/D clutch (E) is applied, SSD increases
pressure to the clutch E regulator and latch valve.
The clutch E regulator valve provides regulated line pressure from the DRIVE circuit to the CLE circuit to
apply the O/D clutch (E).
To release the O/D clutch (E), the manual valve can be in any position. SSD lowers pressure to the VFS4
circuit which lowers pressure in the CLEC and CLEC F circuits and releases the O/D clutch (E). SSE blocks
SREG pressure to the solenoid multiplex valve and the drive enable valve to allow SSD to control low/reverse
clutch (D) operation.
When the O/D clutch (E) is released, the clutch E regulator valve directs exhaust circuit pressure from the CL
EXH circuit to the CL E circuit to fill the circuit and the clutch with fluid at low pressure, approximately 21
kPa (3 psi).



6R80 Manual
Transmission Electronic Control System
The Transmission Control Module (TCM) controls the functions of this transmission. The TCM is part of a
molded plastic leadframe module that is bolted to the mechatronic assembly. The leadframe module also has
the Turbine Shaft Speed (TSS) sensor, Output Shaft Speed (OSS) sensor, Transmission Range (TR) sensor
and Transmission Fluid Temperature (TFT) sensor integrated into it.
The TCM responds to inputs froe sensors and from the vehicle Controller Area Network (CAN) signal. The
TCM uses the inputs to control the line pressure, shift and TCC solenoids. The TCM also provides power and
ground for the reverse lamp relay coil and provides a PARK/NEUTRAL start enable signal.
The TCM uses the following input from the vehicle CAN signal:
Engine speed
Engine torque
Engine Coolant Temperature (ECT)
Engine Oil Temperature (EOT)
Throttle Position (TP)
Accelerator Pedal Position (APP)
Brake Pedal Position (BPP)
ABS wheel speed
Automatic Traction Control (ATC) status
Four-Wheel Drive (4WD) status
The TCM also:
monitors inputs and outputs for the presence of faults.

stores DTCs related to detected faults.
supplies output to the vehicle CAN for TR position, OSS , TSS , TFT , current gear and A/C inhibit.
provides On-Board Diagnostic (OBD) information using the CAN signal to illuminate the
Malfunction Indicator Lamp (MIL) or Transmission Control Indicator Lamp (TCIL).
displays diagnostic information to a scan tool through the Data Link Connector (DLC).
Transmission Electronic Control System 2432

Part
1 - Turbine Shaft Speed (TSS) sensor
2 - Output Shaft Speed (OSS) sensor
3 - Transmission Control Module (TCM)
4 - Transmission Fluid Temperature (TFT) sensor
5 - Transmission Range (TR) sensor
7 - Controller Area Network (CAN) + terminal
8 - CAN - terminal
9 - Reverse lamp relay power
10 - PARK/NEUTRAL start enable signal terminal
11 7G383 Torque Converter Clutch (TCC) Variable Force
Solenoid (VFS)
12 7G484 Shift Solenoid E (SSE) (ON/OFF)
14 7G383 Line Pressure Control (LPC) solenoid
16 7G383 Shift Solenoid B (SSB) VFS
17 7G383 Shift Solenoid A (SSA) VFS
If the TCM detects a fault, it uses Failure Management and Effects Mode strategies to substitute a value or
signal.
The TCM also uses Failure Management and Effects Mode strategies to compensate for detected solenoid or
apply component faults that result in alternate shift patterns.
Transmission Control Module (TCM) 2433

If the transmission loses complete electronic control, it will operate in a failsafe mode with:
Maximum line pressure in all transmission ranges

Functional PARK, REVERSE and NEUTRAL positions
Operation in 3rd or 5th gear (depending on the failure conditions) when the selector lever is in the
DRIVE, 3, 2 or 1 position
TCC is released in all transmission ranges and gears
Solenoid Application Chart
SS E
SS B (VFS2) SS D (VFS4) PC A (VFS5) (SS1)
SS A (VFS1) Inversely SS C (VFS3) Inversely Inversely TCC (VFS6) ON/
Gear Proportional Proportional Proportional Proportional Proportional Proportional OFF
Park X a
Reverse X X a
Neutral X a
1st Gear X X a a
Manual
2nd X X a a
Gear
Manual
3rd X X a a
Gear
Manual
1st Gear X X a a
D
2nd X X a a
Gear D
3rd X X a a
Gear D
4th X X a a X
Gear D
5th X X a a X
Gear D
6th X X a a X
Gear D
a Transmission control module (TCM) controlled
Line Pressure Control (LPC) Solenoid
The Line Pressure Control (LPC) solenoid is a Variable Force Solenoid (VFS) that varies hydraulic pressure
by actuating a hydraulic valve.
The TCM applies variable current to the LPC solenoid which varies pressure in the VFS5 hydraulic circuit to
the Main Regulator Valve. Refer to Hydraulic Circuits in this section for information.
Transmission Control Module (TCM) 2434

The LPC solenoid uses inversely proportional operation. As the current from the TCM decreases, the pressure
from the solenoid increases. As the current from the TCM increases, the pressure from the solenoid decreases.
The LPC solenoid is supplied hydraulic pressure from the SREG circuit.
With zero current, the LPC solenoid fully opens the hydraulic valve which applies the maximum amount of
hydraulic pressure to the Main Regulator Valve through the VFS5 hydraulic circuit and applies maximum line
pressure in the PUMP hydraulic circuit. With maximum current to the solenoid, the hydraulic valve fully
closes the outlet port for minimum pressure to the VFS5 hydraulic circuit to lower the line pressure in the
PUMP hydraulic circuit.
Line Pressure Control (LPC) Inversely Proportional Variable Force Solenoid (VFS)
Torque Converter Clutch (TCC) Solenoid
The TCC solenoid is a VFS that varies hydraulic pressure by actuating a hydraulic valve.
The TCM applies variable current to the TCC solenoid which varies pressure in the VFS6 hydraulic circuit to
the Converter Release Regulator Valve and the Bypass Clutch Control Regulator Valve. Refer to Hydraulic
Circuits in this section.
The TCC solenoid uses proportional operation. As the current from the TCM decreases, the pressure from the
solenoid decreases. As the current from the TCM increases, the pressure from the solenoid increases. The
TCC solenoid is supplied hydraulic pressure from the SREG circuit.
With zero current, the TCC solenoid fully closes the hydraulic valve which applies the minimum amount of
hydraulic pressure to the Converter Release Regulator Valve and the Bypass Clutch Control Regulator Valve
through the VFS6 hydraulic circuit and releases the TCC . With maximum current to the solenoid, the
hydraulic valve fully opens the outlet port for maximum pressure to the VFS6 hydraulic circuit to apply the
TCC .
Line Pressure Control (LPC) Inversely Proportional Variable Force Solenoid (VFS) 2435
Torque Converter Clutch (TCC) Proportional Variable Force Solenoid (VFS)
Shift Solenoid A (SSA), Shift Solenoid B (SSB), Shift Solenoid C (SSC) and Shift Solenoid D (SSD)
Shift solenoids A through D are variable force type solenoids that vary hydraulic pressure by actuating a
hydraulic valve.
The TCM applies variable current to the shift solenoids which varies pressure in the hydraulic circuit to the
regulator and latch valves of the clutch that it controls. Refer to Hydraulic Circuits in this section.
Shift Solenoid A (SSA) and Shift Solenoid C (SSC) use proportional operation. As the current from the TCM
decreases, the pressure from the solenoid decreases. As the current from the TCM increases, the pressure from
the solenoid increases. SSA and SSC are supplied hydraulic pressure from the SREG circuit.
With zero current, SSA and SSC fully close the hydraulic valves which applies zero amount of hydraulic
pressure to the regulator and latch valves of the clutch that it controls and releases the clutch. With maximum
current to the solenoids, the hydraulic valves fully open for maximum pressure to the regulator and latch
valves to apply the clutch.
Shift Solenoid A (SSA) and Shift Solenoid C (SSC) Proportional Variable Force Type Solenoids
Torque Converter Clutch (TCC) Proportional Variable Force Solenoid (VFS) 2436

1 7G383 Shift Solenoid A (SSA) Variable Force Solenoid
(VFS)
Shift Solenoid B (SSB) and Shift Solenoid D (SSD) use inverse proportional operation. As the current from
the TCM decreases, the pressure from the solenoid increases. As the current from the TCM increases, the
pressure from the solenoid decreases. SSB and SSD are supplied hydraulic pressure from the SREG circuit.
With zero current, SSB and SSD fully open the hydraulic valves which applies maximum hydraulic pressure
to the regulator and latch valves to apply the clutch that it controls. With maximum current to the solenoids,
the hydraulic valve fully closes to apply zero amount of hydraulic pressure to the regulator and latch valves of
the clutch that it controls and releases the clutch.
Shift Solenoid B (SSB) and Shift Solenoid D (SSD) Inverse Proportional Variable Force Type Solenoids
Shift Solenoid A (SSA) and Shift Solenoid C (SSC) Proportional Variable Force Type Solenoids2437

1 7G383 Shift Solenoid B (SSB) Variable Force Solenoid (VFS)
Shift Solenoid E (SSE)
Shift Solenoid E (SSE) is an ON/OFF solenoid. When SSE is in the OFF position, SSD controls the regulator
and latch valves to apply the low/reverse clutch. When SSE is in the ON position, SSD controls the regulator
and latch valves to apply the Overdrive (O/D) (456) clutch. Refer to Hydraulic Circuits in this section.
SSE is supplied hydraulic pressure from the SREG circuit. When SSE is OFF, the solenoid supply is blocked
and the outlet port (SS1 circuit) is connected to the exhaust port. When SSE is ON, the exhaust port is blocked
and the solenoid supply is connected to the outlet port (SS1 circuit).
Shift Solenoid E (SSE) ON/OFF Solenoid
Shift Solenoid B (SSB) and Shift Solenoid D (SSD) Inverse Proportional Variable Force Type Solenoids
2438
Turbine Shaft Speed (TSS) Sensor
The TSS sensor connects to the TCM through wiring inside the leadframe module assembly.
The TSS sensor is a Hall-effect type sensor that provides a signal to the TCM that changes in frequency as the
rotating speed of the forward (1234) clutch cylinder varies.
The TCM compares the TSS sensor signal with the engine speed information to determine the amount of slip
occurring in the torque converter.
The TCM also compares the TSS sensor signal with the OSS sensor signal to determine the gear ratio
provided by the rear planetary gearset.
The TCM uses the TSS sensor signal as an input for its strategies for shifts and TCC operation. The TCM also
uses the TSS sensor signal for transmission fault detection and diagnostics.
Refer to the component illustration at the beginning of this procedure for the location of the TSS sensor.
Output Shaft Speed (OSS) Sensor
The OSS sensor connects to the TCM through wiring inside the leadframe module assembly.
The OSS sensor is a Hall-effect type sensor that provides a signal to the TCM that changes in frequency as the
rotating speed of the output shaft ring gear varies.
The TCM also compares the OSS sensor signal with the TSS sensor signal to determine the gear ratio
provided by the rear planetary gearset.
The TCM uses the OSS sensor signal as an input for its strategies for shifts and TCC operation. The TCM also
uses the OSS sensor signal for transmission fault detection and diagnostics.
Shift Solenoid E (SSE) ON/OFF Solenoid 2439

Refer to the component illustration at the beginning of this procedure for the location of the OSS sensor.
Transmission Fluid Temperature (TFT) Sensor
The TFT sensor connects to the TCM through wiring inside the leadframe module assembly.
The TFT sensor is a temperature dependent resistor that is in contact with transmission fluid in the
transmission sump area.
The TCM monitors the voltage across the TFT sensor, which changes as TFT varies.
The TCM uses the TFT sensor signal as an input for its strategy for shifting and TCC operation. The TCM
also uses the TFT sensor signal for transmission fault detection and diagnostics.
Refer to the component illustration at the beginning of this procedure for the location of the TFT sensor.
Transmission Range (TR) Sensor
The TR sensor connects to the TCM through wiring inside the leadframe module assembly.
The TR sensor has a set of Hall-effect sensors that have a pattern of ON/OFF states which are dependant on
the PARK, REVERSE, NEUTRAL, DRIVE, 3, 2 or 1 position of the manual valve.
The TR sensor also provides signals for the starting system and the reverse lights.
The TCM uses the TR sensor signal as an input for its strategy for shifting and TCC operation. The TCM also
uses the TR sensor signal for transmission fault detection and diagnostics.
Refer to the component illustration at the beginning of this procedure for the location of the TR sensor.
Shift Solenoid E (SSE) ON/OFF Solenoid 2440


6R80 Manual
Transmission Operation
Transmission Operation Overview
Torque Converter
This transmission uses a torque converter with the following elements:
Impeller
Turbine
Reactor
For component information, refer to Torque Converter Contamination Inspection in this section.
Planetary Gearsets
Operation of this transmission involves the use of 2 planetary gearsets that have the following components:
Front (si planetary gearset)

One sun gear
One planetary carrier with 4 gears
One ring gear
Rear (ravigenaux planetary gearset)
Two sun gears of different sizes
Three short planetary gear pinions meshing with the sun gears
Three long planetary gear pinions meshing with the sun gears
One ring gear
Apply Clutches
This transmission uses the following clutches to operate the 2 planetary gearsets:
Forward clutch (A)

Direct clutch (B)
Intermediate clutch (C)
Low/reverse clutch (D)
Overdrive clutch (E)
For information about planetary gearsets or the apply clutches, refer to Mechanical Components and
Functions in this section.
Hydraulic System
The hydraulic operation of this transmission includes the following components:
Transmission Operation 2441

Main control (mechatronic) assembly with integrated Transmission Control Module (TCM)
Pump assembly with filter
Torque converter
Apply components (clutches)
For component information, refer to Hydraulic System in this section.
Electronic Operation
The TCM controls the operation of this transmission with the following solenoids:
Line Pressure Control (LPC) solenoid

Shift Solenoid A (SSA) Variable Force Solenoid (VFS)
Shift Solenoid B (SSB) VFS
Shift Solenoid C (SSC) VFS
Shift Solenoid D (SSD) VFS
Shift Solenoid E (SSE) ON/OFF solenoid
TCC solenoid VFS
For solenoid information, refer to Transmission Electronic Control System in this section.
Park Position
Mechanical Operation
Apply components:
Park pawl engaged holding the park gear (output shaft) stationary
Low/reverse clutch (D) applied
Mechanical Operation 2442

Planetary Gearset Operation
Front planetary gearset driving components:
Ring gear (input shaft)
Front planetary gearset driven components:
Planetary carrier
Front planetary gearset held components:
Sun gear (splined to pump assembly)
Rear planetary gearset driving components:
None
Rear planetary gearset driven components:
None
Rear planetary gearset held components:
Planetary carrier
Ring gear (output shaft)
Park Position Clutch Application Chart
Gear/Manual Lever Low/ Reverse

Position Forward (A) Direct (B) Intermediate (C) (D) Overdrive (E)
PARK X
For component information, refer to Mechanical Components and Functions in this section.
Park Position Power Flow
Planetary Gearset Operation 2443

Hydraulic Operation
Line pressure hydraulic circuits:
The position of the main regulator valve controls line pressure. The position of the main regulator
valve is dependent on the pressure applied to it by the LPC solenoid through the VFS5 circuit.
The main regulator valve varies pressure in the PUMP circuit by controlling hydraulic flow from the
SCHG circuit into the pump suction circuit.
Line pressure is supplied to the:
manual valve.
lubrication control valve.
converter release regulator valve.
bypass clutch control regulator valve.
solenoid pressure regulator valve.
D1 and D2 latch and regulator valves.
Torque converter circuits:
When the TCC is released, the converter release regulator valve applies pressure to the torque
converter through the CREL circuit to release the TCC .
CREL pressure exits the torque converter through the CAPLY circuit to the bypass clutch control
regulator valve.
The bypass clutch control regulator valve directs the pressure from the CAPLY circuit back to the
converter release regulator valve through the CAPLY EX circuit.
The converter release regulator valve directs the pressure from the CAPLY EX circuit to the drain
back valve through the DBACK circuit.
Cooler and lubrication hydraulic circuits:
The lubrication control valve directs line pressure to the transmission fluid cooler or the thermal
bypass valve through the COOLF circuit.
When the transmission fluid exits the transmission fluid cooler or thermal bypass valve, it provides
lubrication to the transmission through the LUBE circuit. For information about transmission
lubrication, refer to Mechanical Components and Functions in this section.
Solenoid hydraulic circuits:
The solenoid pressure regulator valve supplies regulated line pressure to the shift, LPC and TCC
solenoids through the SREG hydraulic circuit.
The LPC solenoid applies varying pressure to the main regulator valve through the VFS5 hydraulic
circuit. The LPC solenoid regulates line pressure by controlling the position of the main regulator
valve.
SSD supplies pressure to the solenoid multiplex valve through the VFS4 circuit.
The position of the solenoid multiplex valve allows pressure from the VFS4 circuit to be directed to
the D1 and D2 latch and regulator valves through the CL DC circuit to position the valves for
low/reverse clutch (D) application.
Clutch hydraulic circuits:
Line pressure is supplied by the pump to the D1 and D2 latch and regulator valves.
Regulated line pressure from the D1 and D2 regulator valves is supplied to the low/reverse clutch (D)
to apply the clutch.
For hydraulic circuit information, refer to Hydraulic Circuits in this section.
Hydraulic Operation 2444

Electrical Operation
Solenoid operation:
Park Position Solenoid Operation Chart
SSB (VFS) SSD (VFS) LPC (VFS)

SSA (VFS) Inversely SSC (VFS) Inversely SSE Inversely TCC (VFS)
Gear Proportional Proportional Proportional Proportional (ON/OFF) Proportional Proportional
Park X X
Printable / zoomable view of this graphic
Reverse Position
Electrical Operation 2445

Apply components:

Direct clutch (B) applied (quantity model dependant)
Steel
Planetary carrier

Sun gear No. 2
Planetary carrier
Reverse Position Clutch Application Chart

Reverse X X
Reverse Position Power Flow
Hydraulic Operation
manual valve.
In reverse, the manual valve directs line pressure to the No. 1 shuttle valve and the solenoid multiplex
valve through the REV circuit.
The No. 1 shuttle ball directs line pressure to the clutch B regulator valve.

regulator valve.
valve.
the D1 and D2 latch and regulator valves through the CLDC circuit to position the valves for
SSB supplies pressure to the clutch B regulator and latch valves to position the valves for direct clutch
(B) application.
Line pressure is supplied by the manual valve to the clutch B latch and regulator valves.
Regulated line pressure from the clutch B regulator valve is supplied to the direct clutch (B) to apply
the clutch.
Solenoid operation:
Reverse Position Solenoid Operation Chart
Gear SSA (VFS) SSB (VFS) SSC (VFS) SSD (VFS) SSE LPC (VFS) TCC (VFS)

Proportional Inversely Proportional Inversely (ON/OFF) Inversely Proportional

Proportional Proportional Proportional
Reverse X X X
Neutral Position

Apply components:
Planetary carrier
None
None
Planetary carrier
Neutral Position Clutch Application Chart

Neutral X
Neutral Position Power Flow

Hydraulic Operation
manual valve.
regulator valve.
valve.
the D1 and D2 latch and regulator valves through the CL DC circuit to position the valves for
Neutral Position Power Flow 2451

Solenoid operation:
Neutral Position Solenoid Operation Chart

Neutral X X
1st Gear

Apply components:

Forward clutch (A) applied (quantity model dependant)
Steel
Planetary carrier

No. 3 sun gear
Planetary carrier
1st Gear Clutch Application Chart

1st Gear X X
Power Flow
Hydraulic Operation
manual valve.
In drive, the manual valve directs line pressure to the No. 1 shuttle valve and clutch A, C and E
regulator valves.

regulator valve.
valve.
the D1 and D2 latch and regulator valves through the CLDC circuit to position the valves for
SSA supplies pressure to the clutch A regulator and latch valves to position the valves for forward
clutch (A) application.
Regulated line pressure from the clutch A regulator valve is supplied to the forward clutch (A) to
apply the clutch.
Solenoid operation:
1st Gear Solenoid Operation Chart
Gear SSA (VFS) SSB (VFS) SSC (VFS) SSD (VFS) SSE LPC (VFS) TCC (VFS)
Proportional Inversely Proportional Inversely (ON/OFF) Inversely Proportional

Proportional Proportional Proportional

1st X X X
Gear
2nd Gear

Apply components:

Intermediate clutch (C) applied (quantity model dependant)
Steel
Steel
Planetary carrier
No. 3 sun gear
Planetary carrier

No. 2 sun gear
2nd Gear Clutch Application Chart

2nd Gear X X
Power Flow
Hydraulic Operation
manual valve.
regulator valves.

regulator valve.
valve.
SSC supplies pressure to the clutch C regulator valve to position the valve for intermediate clutch (C)
application.
apply the clutch.
Regulated line pressure from the clutch C regulator valve is supplied to the intermediate clutch (C) to
apply the clutch.
Solenoid operation:
2nd Gear Solenoid Operation Chart

2nd X X X
Gear

3rd Gear
Apply components:


Steel
Steel
Planetary carrier
No. 3 sun gear

No. 2 sun gear
Planetary carrier
None

3rd Gear Clutch Application Chart

3rd Gear X X
Power Flow
Hydraulic Operation
manual valve.
regulator valves.
regulator valve.

valve.
SSB supplies pressure to the clutch B regulator valve to position the valve for direct clutch (B)
application.
apply the clutch.
the clutch.
Solenoid operation:
3rd Gear Solenoid Operation Chart

3rd X X X
Gear

4th Gear
Apply components:

Overdrive (O/D) clutch (E) applied

Steel
Planetary carrier
No. 3 sun gear

Planetary carrier
None
4th Gear Clutch Application Chart

4th Gear X X
Power Flow

Hydraulic Operation
manual valve.
regulator valves.
regulator valve.
valve.
Power Flow 2466

SSE supplies pressure to the solenoid multiplex valve and the drive enable valve through the SS1
circuit to move the valves.
The position of the solenoid multiplex valve and the drive enable valve allows pressure from the
VFS4 circuit to be directed to the clutch E latch and regulator valves through the CLEC circuit to
position the valves for O/D clutch (E) application.
apply the clutch.
Regulated line pressure from the clutch E regulator valve is supplied to the O/D clutch (E) to apply
the clutch.
Solenoid operation:
4th Gear Solenoid Operation Chart

4th X X X X
Gear

5th Gear
Apply components:
O/D clutch (E) applied


Steel
Planetary carrier
No. 2 sun gear

Planetary carrier
None
5th Gear Clutch Application Chart

5th Gear X X
Power Flow

Hydraulic Operation
manual valve.
regulator valves.
regulator valve.
valve.
Power Flow 2470

SSB supplies pressure to the clutch B regulator valve to position the valve for direct clutch (B)
application.
the clutch.
the clutch.
Solenoid operation:
5th Gear Solenoid Operation Chart

5th X X X X
Gear

6th Gear Torque Converter Clutch (TCC) Applied
Apply components:
O/D clutch (E) applied

Intermediate clutch (C) applied (quantity model dependant)

Steel
Planetary carrier (does not contribute to power flow)
Planetary carrier
No. 2 sun gear
6th Gear Torque Converter Clutch (TCC) Applied Clutch Application Chart
Gear/Manual Lever Forward Direct Intermediate Low/ Reverse Overdrive

Position (A) (B) (C) (D) (E) TCC
6th Gear X X X
Power Flow

Hydraulic Operation
manual valve.
regulator valves.
When the TCC is applied, the bypass clutch control regulator valve applies pressure to the torque
converter through the CAPLY circuit to apply the TCC .
CAPLY pressure exits the torque converter through the CREL circuit to the converter release
regulator valve.
valve.
The TCC solenoid supplies pressure to the converter release regulator valve and the bypass clutch
control regulator valve to move the position of the valves for TCC application.
SSC supplies pressure to the clutch C regulator valve to position the valve for intermediate clutch (C)
application.
Power Flow 2474

Regulated line pressure from the clutch C regulator valve is supplied to the intermediate clutch (C) to
apply the clutch.
the clutch.
Solenoid operation:
6th Gear Torque Converter Clutch (TCC) Applied Solenoid Operation Chart

6th X X X X X
Gear

3rd Gear Fail Safe
Apply components:


Steel
Steel
Planetary carrier
No. 3 sun gear

No. 2 sun gear
Planetary carrier
None

3rd Gear Fail Safe Clutch Application Chart

3rd Gear X X
Power Flow
Hydraulic Operation
manual valve.
regulator valves.
regulator valve.

The solenoid pressure regulator valve supplies line pressure to the shift, LPC and TCC solenoids
through the SREG hydraulic circuit.
The LPC solenoid applies full solenoid output pressure to the main regulator valve through the VFS5
hydraulic circuit. With full solenoid output pressure, the main regulator valve provides maximum line
pressure during fail safe.
SSB supplies maximum solenoid output pressure to the clutch B regulator valve to position the valve
for direct clutch (B) application.
Regulated line pressure from the clutch B regulator valve is supplied to the direct clutch (B) to, apply
the clutch. Regulated line pressure from the clutch B regulator valve is also supplied to the clutch A
latch valve from the clutch B latch valve through the BREV 5F circuit.
The clutch A latch valve directs the regulated line pressure to the drive enable valve through the
BREV5 circuit.
The drive enable valve directs the BREV5 pressure to the BREVA circuit which supplies the clutch A
regulator valve to position the valve to apply the forward clutch (A) with 81% of line pressure.
Solenoid operation:
3rd Gear Fail Safe Solenoid Operation Chart

3rd - - - - - - -
Gear



6R80 Manual
Diagnostic Strategy
Troubleshooting an electronically controlled automatic transmission is simplified by using the proven method
of diagnosis. One of the most important things to remember is that there is a definite procedure to follow.
NOTE: Do not take short cuts or assume that critical checks or adjustments have already been made.
Follow the procedures as written to avoid missing critical components or steps.
To correctly diagnose a concern, have the following publications available:
Powertrain Control/Emissions Diagnosis (PC/ED) manual

On-Line Automotive Service Information System (OASIS)
TSBs
Wiring Diagrams manual
Use the Diagnostic Flow Chart as a guide and follow the steps as indicated.
Preliminary Inspection
Know and understand the customer concern.

Verify the concern by operating the vehicle.
Check the transmission fluid level and condition.
Check for non-factory add-on items.
Check selector lever cable for correct adjustment.
Check TSBs regarding the concern.
Diagnostics
Carry out On-Board Diagnostic (OBD) procedures, Key ON Engine OFF (KOEO) and Key
ON Engine Running (KOER).
Record all DTCs.
Repair all non-transmission codes first.
Repair all transmission codes second.
Clear all continuous codes and attempt to repeat them.
Repair all continuous codes.
If only codes that have passed are obtained, refer to Diagnosis By Symptom in this section for
additional information and diagnosis.
Follow the diagnostic sequence to diagnose and repair the concern the first time.
Diagnostic Strategy 2481

Diagnostic Strategy 2482


6R80 Manual
Diagnostic Flow Chart
Special Tool(s)

Prior to carrying out the flow test, the following items should be checked:
Know and understand the customer concerns.

Verify the concern by operating the vehicle.
Check the transmission fluid level and condition.
Check for non-factory-insta items and verify correct installation.
Check the selector lever cable adjustments.
Check TSBs for vehicle concerns.
Carry out Self Test both Key ON Engine OFF (KOEO) and Key ON Engine Running (KOER).
Record all DTCs.
Verify the vehicles PCM and Transmission Control Module (TCM) is programmed to the latest
calibration level.
Diagnostic Flow Chart

1) Were any DTCs recorded? Yes
REPAIR all DTCs. FOLLOW the pinpoint tests. REFER to the
Powertrain Control/Emissions Diagnosis (PC/ED) manual, then
this workshop manual, GO to Step 2.
No
REFER to Diagnosis By Symptom in this section, GO to Step 5.
2) Are any continuous test Yes
memory codes present? CLEAR codes and CARRY OUT drive cycle test, GO to Step 3.
No
GO to Step 4.
3) Did the continuous test Yes
memory codes reappear? REPAIR all continuous test memory codes. FOLLOW the
pinpoint tests. REFER to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual, then this workshop manual, GO to
Step 4.
No
GO to Step 4.
4) Is the concern repaired? Yes
CARRY OUT the final self-test to verify that no DTCs are
present. CLEAR the DTCs.
No
Diagnostic Flow Chart 2483

REFER to Diagnosis By Symptom in this section to diagnose and

repair the concern, GO to Step 5.
5) Are there any electrical Yes
concerns? INSTALL the scan tool and CARRY OUT the output state
control test, GO to Step 6.
No
REFER to the hydraulic and mechanical routine to DIAGNOSE
and REPAIR the concern, GO to Step 7.
6) Was the transmission Yes
concern corrected when the REFER to the Powertrain Control/Emissions Diagnosis (PC/ED)
scan tool was installed? manual, intermittent fault diagnosis section and use the scan tool
to diagnose cause of concern in the processor, vehicle harness of
external inputs (sensors or switches).
No
REFER to the hydraulic and mechanical routine to DIAGNOSE
and REPAIR the concern, GO to Step 7.
7) Is the concern repaired? Yes
CARRY OUT the final self-test and verify that no DTCs are
present. CLEAR the DTCs.
No
Concern should have been repaired. RETURN to the Diagnostic
Flow Chart and REVIEW other components that may have
contributed to the concern. CHECK and DIAGNOSE those
components.
Diagnostic Flow Chart 2484


6R80 Manual
Preliminary Inspection
The following items must be checked prior to beginning the diagnostic procedures:
Know and Understand the Concern
In order to correctly diagnose a concern, first understand the customer concern or condition. Customer contact
may be required in order to begin to verify the concern. Understand the conditions, including when the
concern occurs. For example:
Hot or cold vehicle temperature

Hot or cold ambient temperature
Vehicle driving conditions
Vehicle loaded/unloaded
After understanding when and how the concern occurs, proceed to Verification of Condition.
Verification of Condition
This section provides information that must be used in both determining the actual cause of customer concerns
and carrying the appropriate procedures.
The following procedures must be used when verifying customer concerns for the transmission.
Determine Customer Concern
Determine customer concerns relative to vehicle use and dependent driving conditions, paying attention to the
following items:
Hot or cold vehicle operating temperature

Hot or cold ambient temperature
Type of terrain
Vehicle loaded/unloaded
City/highway driving
Upshifting
Downshifting
Coasting
Engagement
Noise/vibration - check for engine rpm, vehicle speed, shift, gear, range or temperature dependencies.
Check Transmission Fluid Level and Condition
Transmission Fluid Level Check
NOTICE: The vehicle should not be driven if the transmission fluid level is low as internal transmission
failure could result.
Preliminary Inspection 2485

NOTICE: The transmission fluid fill plug is located near the exhaust system. The exhaust will be
extremely hot during this procedure.
NOTE: If the vehicle has been operated for an extended period at high highway speeds, in city traffic, during
hot weather or while pulling a trailer, the transmission fluid must cool down to obtain an accurate reading.
NOTE: If the transmission starts to slip, shifts slowly or shows signs of transmission fluid leaking, the
transmission fluid level should be checked.
This transmission is equipped with an internal thermal bypass located in the case. This internal thermal bypass
valve will shut off transmission fluid flowing to the transmission fluid cooler if the transmission fluid
temperature falls below normal operating temperature. Refer to Transmission Fluid Level Check in this
section.
The transmission can have 2 types of transmission fluid level indicators, the original or the replacement. The
original transmission fluid level indicator has a single crosshatch area for the fluid level. The replacement has
2 areas for the fluid level, a crosshatched (labeled A) area and a dotted (labeled B) area. Use the crosshatched
area when checking the transmission fluid level. The correct transmission fluid level is at the upper level of
the crosshatch marks on the transmission fluid level indicator.
1 Original transmission fluid level

indicator
2 Replacement transmission fluid level
indicator
High Transmission Fluid Level
NOTICE: A transmission fluid level that is too high can cause the transmission fluid to become aerated
due to the churning action of the rotating internal parts. This will cause erratic control pressure,
foaming, loss of transmission fluid from the vent tube and possible transmission failure.
If an overfill reading is indicated, remove any excessive transmission fluid. Refer to Transmission Fluid Level
Check in this section.
Low Transmission Fluid Level

Low transmission fluid level can result in poor transmission engagement, slipping or failure. This may also
indicate a leak in one of the transmission seals or gaskets.
Adding Transmission Fluid
NOTICE: The use of any type of transmission fluid other than specified can result in transmission
failure.
NOTICE: The vehicle should not be driven if the transmission fluid level is low as internal failure could
result.
Add transmission fluid using the refill procedure. Refer to Transmission Fluid Drain and Refill in this section.
Transmission Fluid Condition Check
1. Check the transmission fluid level.
2. Remove the transmission fluid fill plug and transmission fluid level indicator allowing the
transmission fluid to drip onto a facial tissue and examine the stain.
3. Observe the color and the odor.
4. If evidence of solid material is found, remove the transmission fluid pan for further inspection.
5. If the stain is a foamy pink color, this may indicate coolant in the transmission. Inspect the engine
cooling system at this time.
6. If transmission fluid contamination or transmission failure is confirmed by the sediment in the bottom
of the transmission fluid pan, disassemble and completely clean the transmission. This includes the
torque converter and transmission fluid cooler tubes. Install a new auxiliary transmission fluid cooler.
Water in Transmission Fluid
To correctly repair an automatic transmission that had water or coolant introduced into the system, completely
disassemble, clean and replace the following parts:
All internal and external seals

All friction material
Torque converter
All parts with bonded seals
All solenoids
All transmission fluid filters
Prior to installing the transmission, the transmission fluid cooler(s), transmission fluid cooler tubes and hoses
need to be flushed and cleaned.



6R80 Manual
Shift Point Road Test
Special Tool(s)

This test verifies the shift control system is operating correctly.
1. Bring engine and transmission up to normal operating temperature.
2. Operate vehicle with the selector lever in Overdrive (O/D) position.
3. Apply minimum thle and observe speeds at which upshift occurs and the torque converter engages.
Refer to the Shift Speeds chart in this section.
4. With the selector lever in O/D , move the selector lever into the manual 3 position. The transmission
should downshift to 4th gear. Release the accelerator pedal; engine braking should occur.
5. Press the accelerator pedal to floor, Wide Open Throttle (WOT). Transmission should shift from 4th
to 3rd, depending on vehicle speed. The torque converter should disengage and then reapply.
6. With the selector lever in the Overdrive (O/D) position and vehicle speed above 80 km/h (50 mph)
and less than half throttle, move the selector lever from the O/D position to manual 2 position and
release the accelerator pedal. The transmission should downshift into 2nd gear. With the transmission
remaining in the manual 2 position, move the selector lever into the manual 1 position and release the
accelerator pedal. The transmission should downshift into 1st gear at speeds below approximately
45-56 km/h (28-35 mph).
7. If the transmission fails to upshift/downshift or the torque converter does not apply and release, refer
to Diagnosis By Symptom in this section.
Shift Speeds
NOTE: Shift speed ranges are approximate for all applications. For specific applications (engine, axle
ratio, tire size and application), refer to the Automatic Transmission Specification booklet. Always
drive the vehicle in a safe manner according to driving conditions and obey all traffic laws.
Throttle Position Shift Km/H MPH

Light Throttle 1-2 13-21 8-13
Throttle Position (TP) Sensor 2-3 26-34 16-21
Voltage @ 1.25 Volts 3-4 35-43 22-27
4-5 56-64 35-40
5-6 71-79 44-49
Shift Point Road Test 2489

Closed Throttle 6-5 56-64 35-40

5-4 40-48 25-30
4-3 13-21 8-13
3-2 3-11 2-7
2-1 2-6 1-4
Wide Open Throttle (WOT) 1-2 45-53 28-33
2-3 87-95 54-59
3-4 140-148 87-92
Road Test - Adaptive Drive Cycle
1. Connect the scan tool to the Data Link Connector (DLC).
2. NOTE: Disconnecting the battery will not clear the Keep Alive Memory (KAM).
NOTE: Do not clear the PCM KAM .
Using the scan tool, clear the Transmission Control Module (TCM) KAM and the adaptive table
before conducting an adaptive drive cycle test.
3. Using the scan tool verify the transmission fluid is at normal operating temperature, between
80C-82C (176F-180F). If the transmission fluid is not at operating temperature, drive the vehicle
approximately 5 km (3.1 mi) to reach operating temperature.
4. NOTE: The transmission fluid must be at operating temperature before proceeding to this step.
Drive the vehicle to perform adaptive shift strategy learn on a level road surface.
1. Accelerate from a stop with light throttle to 24 km/h (15 mph) and then release the accelerator
pedal.
2. Gently brake and bring the vehicle to a stop and hold the brake for 6 seconds.
3. Repeat Substeps 1 and 2 an additional 5 times.
4. Accelerate from a stop with light throttle so the 1-2, 2-3 and 3-4 shifts occur with engine
speeds between 1,700-2,000 rpm.
5. Continue accelerating until either the vehicle speed reaches 80(50 mph) or the 5-6 upshift is
reached.
6. Gently brake and bring the vehicle to a stop and hold the brake for 10 seconds.
7. Repeat Substeps 4, 5 and 6 an additional 3 times.



6R80 Manual
Torque Converter Diagnosis
Special Tool(s)

Prior to torque converter installation, all diagnostic procedures must be followed. This is to prevent the
unnecessary installation of good torque converters. Only after a complete diagnostic evaluation can the
decision be made to install a new torque converter.
Begin with the normiagnostic procedures as follows:
1. Preliminary inspection.
2. Know and understand the customer concern.
3. Verify the condition - carry out the Torque Converter Operation Test.
4. Perform diagnostic procedures.
Perform On-Board Diagnostic (OBD) test. Refer to Diagnostics in this section.

Repair all non-transmission related DTCs first.
Repair all transmission-related DTCs.
Rerun OBD test to verify repair.
Perform Stall Speed Test. Refer to Special Testing Procedures in this section.
Perform Diagnostic Routines. Refer to Diagnosis By Symptom in this section.
Use the Diagnosis by Symptom to locate the appropriate routine that best describes the
symptom(s). The routine will list all possible components that may cause or contribute to the
symptom. Cck each component listed; diagnose and repair as required before changing the
torque converter.
Torque Converter Operation Test
The Torque Converter Operation Test verifies the Torque Converter Clutch (TCC) control system and the
torque converter are operating correctly.
1. Perform a self-test with the scan tool. Refer to the Powertrain Control/Emissions Diagnosis (PC/ED)
manual. Check for DTCs.
2. Connect a scan tool to the vehicle.
3. Bring the engine to normal operating temperature by driving the vehicle at highway speeds with the
selector lever in the Overdrive (O/D) position.
Torque Converter Diagnosis 2492

4. After normal operating temperature is reached, maintain a constant speed of about 56 km/h (35 mph)
in 5th gear for 10 seconds.
5. Release the accelerator pedal and monitor the scan tool Throttle Position (TP) voltage to
approximately 1.25 volts or 25% throttle.
6. Monitor the TCC and RPM TCM PIDs. The torque converter should release and engine rpms should
increase before the 5-4 shift occurs.
NOTE: The following is a list of common vehicle concerns that have been misdiagnosed as torque converter
shudder. For diagnosis of the following items, refer to the appropriate sections of the workshop manual and
the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Spark plugs - check for cracks, high resistance or broken insulators

Ignition coil-on-plug - misfire
Fuel injector - filter may be plugged
Fuel contamination - engine driveability concerns
EGR valve - valve may let in too much exhaust gas and cause engine to run lean
Vacuum leak - engine will not get correct air/fuel mixture
Manifold Absolute Pressure (MAP) and Mass Air Flow (MAF) sensor - incorrect air/fuel mixture
Fuel pressure - may be too low

Engine mounts - loose/damaged mounts can cause vibration concerns
Axle joints - check for vibration
Torque Converter Diagnosis 2493


6R80 Manual
Visual Inspection
A visual inspection will identify modifications or additions to the vehicle operating system that may affect
diagnosis. Inspect the vehicle for non-Ford factory add-on devices such as:
Electronic add-on items:

A/C
generator (alternator)
engine turbo
cellular telephone
cruise control
CB radio
linear booster
backup alarm signal
computer
Vehicle modification:
These items, if not installed correctly, will affect the PCM or transmission function. Pay particular attention to
add-on wiring splices in the PCM harness or transmission wiring harness, abnormal tire size or axle ratio
changes.
Leaks; refer to Leakage Inspection in this section.

Correct selector lever adjustments; refer to Section 307-05 .
Selector Lever Check
Check for a misadjustment in the selector lever by matching the detents in the Transmission Range (TR)
selector lever with those of the manual control lever in the transmission.
Hydraulic leakage at the manual control valve can cause delay in engagements and/or slipping while operating
if the linkage is not correctly adjusted. Refer to Section 307-05 for selector lever cable adjustment.
Check TSBs and On-Line Automotive Service Information System (OASIS)
Refer to all TSB and On-Line Automotive Service Information System (OASIS) messages that pertain to the
transmission concern and follow the procedure as described.
Carry Out On-Board Diagnostic (OBD) Key ON Engine OFF (KOEO), Key ON Engine Running
(KOER)
After a road test, with the vehicle warm and before disconnecting any connectors, perform a self-test using the
scan tool. Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Visual Inspection 2494

Visual Inspection 2495


6R80 Manual
Diagnostics
Special Tool(s)


Diagnosing an electronically controlled automatic transmission is simplified by using the following
procedures. The most important things to remember is there is a definite procedure to follow. Do not take
shortcuts or assume that critical checks or adjustments have already been made. Follow the procedures as
written to avoid missing critical components or steps. By following the diagnostic sequence, the technician
will be able to diagnose and repair the concern the first time.
On-Board Diagnostic (OBD) with Scan Tool
These self-tests should be used to diagnose the PCM and should be carried out in order.
NOTE: Make sure the latest software version is loaded on the scan tool.
1. If the cause is not visually evident, connect the scan tool to the Data Link Connector (DLC).
NOTE: The Vehicle Communication Module (VCM) LED prove-out confirms power and ground from the
DLC to the VCM .
2. If the scan tool does not communicate with the VCM :

refer to Section 418-00 , No power to the scan tool.

verify the ignition is in the RUN position.
verify scan tool operation with a known good vehicle.
refer to Section 418-00 , The PCM does not respond to the scan tool.
4. Carry out the network test:

If the scan tool responds with no communication from one or more modules, refer to Section
418-00 , No High Speed Controller Area Network (CAN) communication, all modules are not
responding.
If the network test passes, retrieve and record the continuous memory DTCs.
5. Clear the continuous DTCs and carry out the PCM self-test.
6. If DTCs retrieved are related to the concern, GO to the DTC Chart.
Diagnostics 2496
7. If no DTCs related to the concern are retrieved, REFER to Diagnosis By Symptom in this section.
Diagnostics 2497

6R80 Manual
Output State Control (OSC) Mode
On-Board Diagnostic (OBD)
Output state control allows the technician to take control of certain parameters to function the transmission.
Output state control allows the technician to shift the transmission when commanding a gear change.
Another example of the output state control features is, the technician can command the torque converter ON
or OFF to check operation.
This transmission output state control has one mode of operation; DRIVE. This mode has a unique set of
operating requirements that the technician must meet before allowed to operate the torque converter or select
gears.
Output State Control (OSC) Mode 2498


6R80 Manual
Diagnostic Parameters Identification (PID) Chart
The following is a list of output state control parameters and their corresponding PIDs:
Diagnostic PID Chart
PID Name PID Description Units

APP_R Accelerator Pedal Position (APP) Relative 0% - 100%
AST Time Since Start Time
CLRDIST Distance Since Diagnostic Trouble Codes Cleared Miles
DRIVE Gear Lever Position - Drive Yes/No
DTC TCM Continuous Codes Number
ECT TCM Engine Coolant Temperature (ECT) Transmission Control Module Degrees
ENGLOAD Engine Load 0% - 100%
GEAR Gear Commanded by Module 1, 2, 3, 4, 5
GEAR_OSC# Gear Commanded by Output State Control 1, 2, 3, 4, 5
GEAR_RAT_CMD Gear Ratio Commanded Ratio 0-5:1
GEAR_RAT_MES Gear Ratio Measured Ratio 0-5:1
MIL_DIS The Distance Traveled Since the MIL was Activated Miles
NEUTRAL Gear Lever Position - Neutral Yes/No
OSS Output Shaft Speed (OSS) rpm
OSS_SRC Unfiltered OSS rpm
PCA AMP PCA Amp Current
PVT Pressure Vacuum Transducer Pressure
PVT Pressure Vacuum Transducer Vacuum
REVERSE Gear Lever Position - Reverse Yes/No
RPM TCM Engine Revolutions Per Minute rpm
SHIFT_TYPE Shifter Position Mode
SSA_AMP Shift Solenoid Pressure Control A (SSPCA) Current
SSB_AMP Shift Solenoid Pressure Control B (SSPCB) Current
SSC_AMP Shift Solenoid Pressure Control C (SSPCC) Current
SSD_AMP Shift Solenoid Pressure Control D (SSPCD) Current
SSE Shift Solenoid Pressure Control E (SSPCE) 0% - 100%
TCC AMP Torque Converter Clutch (TCC) Solenoid Pressure Control Current
TCC_OSC# TCC Output State Control Locked/Unlocked
TC_SLIPACT Torque Converter Slip Actual rpm
TC_SLIP_ABSL Absolute Value of Torque Converter Slip rpm
TFT Transmission Fluid Temperature (TFT) Temp
TORQUE Net Engine Torque Torque Nm
Diagnostic Parameters Identification (PID) Chart 2499

TP Throttle Position (TP) Sensor 0% - 100%

TR Transmission Range (TR) Sensor Mode
TSS Turbine Shaft Speed (TSS) rpm
TSS_SRC Unfiltered TSS Sensor rpm
VPWR TCM Module Supply Voltage Voltage
VSS Vehicle Speed Sensor (VSS) mph 0-80
WARMUPS Number of Warm-Ups Since DTCs Cleared Number
Diagnostic Parameters Identification (PID) Chart 2500


6R80 Manual
Transmission Drive Cycle Test
Special Tool(s)

Item Specification
Motorcraft MERCON LV MERCON
Automatic Transmission Fluid LV
XT-10-QLVC
NOTE: Always drive the vehicle in a safe manner according to driving conditions and obey all traffic laws.
NOTE: The Transmission Drive Cycle Test must be followed exactly. Malfunctions must occur 4 times
consecutively for a shift error DTC to set, and 5 times consecutively for continuous Torque Converter Clutch
(TCC) DTCs to set.
NOTE: Refer to the Solenoid Application Chart for solenoid operation while performing the Transmission
Drive Cycle Test.
After performing the self-test, follow the transmission drive cycle test for checking codes.
1. Record then clear the DTCs.
2. Warm the engine to normal operating temperature.
3. Make sure the transmission fluid level is correct.
4. With the selector lever in Overdrive (O/D), moderately accelerate from stop to 80 km/h (50 mph)
allowing the transmission to shift into 6th gear. Keep vehicle speed and throttle steady for a minimum
of 15 seconds.
5. With the transmission in 6th gear and maintaining steady speed and throttle, lightly apply and release
the brake pedal to operate the stop lamps. Then, hold vehicle speed and throttle steady for a minimum
of 5 seconds.
6. Brake to a stop and remain stopped for a minimum of 20 seconds.
7. Repeat steps 4 through 6 at least 5 times.
8. Perform a self-test and record DTCs.

If DTCs are present, refer to the DTC Chart. Repair all non-transmission DTCs first as they
can directly affect the operation of the transmission. Repeat the self-test and the road test to
verify the correction. Clear the DTCs. Perform the transmissidrive cycle test and repeat the
self-test after completing the repair.
Transmission Drive Cycle Test 2501

If the tests pass and a concern is present, refer to Diagnosis By Symptom in this section,
OASIS messages and TSBs for concerns.
After On-Board Diagnostic (OBD)
NOTE: The vehicle wiring harness, PCM and non-transmission sensors may affect transmission operations.
Repair these concerns first.
Repair all DTCs after the On-Board Diagnostic (OBD) test procedures are completed.
Begin with non-transmission related DTCs, then repair transmission related DTCs. Use the DTC Chart for
information on condition and symptoms. This chart will be helpful in referring to the correct manual(s) and
aids in diagnosing internal transmission concerns and external non-transmission inputs. The pinpoint tests are
used in diagnosing transmission electrical concerns. Diagnosis the vehicle wiring harness and the PCM as
well. The Powertrain Control/Emissions Diagnosis (PC/ED) manual aids in diagnosing non-transmission
electronic components.
Transmission Drive Cycle Test 2502


6R80 Manual
Diagnostic Trouble Code (DTC) Charts
Special Tool(s)

Using a scan tool to retrieve DTCs, begin with and repair all non-transmission related DTCs. Start with the
U-DTC codes (communication link codes) then repair any transmission-related DTCs.
Limp-home mode is a default condition to protect the engine and transmission when a fault occurs.
Limp-home mode depends on the actual gear the transmission was in when the fault occurred.
For gears 1-3, the limp-home default will be 3rd gear.

For gears 4-6, the limp-home default will be 5th gear.
The limp-home gear will be until the selector lever is placed in REVERSE, PARK or the vehicle has been
restarted. After these action(s) the PCM will default the transmission to the limp-home mode of 3rd gear.
DTC Chart
DTC Component Description Condition Symptom Action

P0218 Transmission TFT condition Transmission PERFORM normal
Fluid Control Module Aggressivediagnostic for an
Temperature (TCM) has lockup overheating condition.
(TFT) detected a TFT schedule REFER to Diagnosis By
that has exceeded Symptom in this section.
a set
temperature.
P0562 Battery System voltage low TCM has CONNECT the scan tool
detected a and monitor the VPWR
Malfunction
voltage level Indicator TCM PID to verify module
below minimum Lamp supply voltage to the TCM .
voltage to (MIL) REFER to Diagnostic
operate ON Parameters Identification
solenoids. Transmission
(PID) Chart in this section.
Maintains Control GO to Pinpoint Test A .
current solenoid Indicator
state. Lamp
(TCIL)
ON
No
adaptive

strategy
No self
learning
strategy
Default
to 3rd or
5th gear
Battery
voltage
below 9
volts
P0563 Battery System voltage TCM has CONNECT the scan tool
high detected a No and monitor the VPWR
voltage level adaptive TCM PID to verify module
above maximum strategy supply voltage to the TCM .
voltage. No self REFER to the Diagnostic
learning Parameters Identification
strategy (PID) Chart and the
MIL may Powertrain
turn ON Control/Emissions
Default Diagnosis (PC/ED) manual.
to 3rd or
5th gear
Battery
voltage
above 16
volts
Will turn
on TCIL
P0605 TCM The TCM TCM has REPROGRAM the original
Read-Only detected an MIL ON mechatronic to the latest
Memory (ROM) internal software TCIL calibration. CLEAR the
has been corrupted concern with ON DTCs. TEST the system for
ROM . Default normal operation. If DTCs
to 3rd or return, INSTALL a new
5th gear mechatronic assembly. After
installing the new
mechatronic assembly, it
must be programmed with
the latest calibration.
PERFORM the Road Test -
Adaptive Drive Cycle.
REFER to Shift Point Road
Test in this section.
P0613 TCM TCM processor TCM has INSTALL a new
detected an MIL ON mechatronic assembly. After
internal software TCIL installing the new
issue. ON mechatronic assembly, it
Default must be programmed with
to 3rd or the latest calibration.
5th gear
P0634 TCM TCM module Internal CONNECT the scan tool
temperature temperature MIL ON and monitor the TFT PID to

within TCM too Default verify that a high

high. to 3rd or temperature is present.
5th gear INSPECT the transmission
Possible fluid cooler tubes for
restriction in possible restrictions (kinked
cooling circuit. or bent cooler tube).
VERIFY correct
operation/orientation of the
thermal bypass valve.
INSTALL a new
mechatronic unit. After
installing the new
mechatronic unit, it must be
programmed with the latest
calibration.
P0641 TCM TCM module Sensor reference INSTALL a new
sensor voltage voltage A circuit MIL ON mechatronic unit. After
failed open, voltage too TCIL installing the new
high or too low. ON mechatronic unit, it must be
Default programmed with the latest
to 3rd or calibration.
5th gear
Low
battery
voltage
under 9
volts.
May also
cause
P0562
P0657 TCM Actuator supply Power supply INSTALL a new
voltage A circuit actuators open MIL ON mechatronic unit. After
open circuit. TCIL installing the new
ON mechatronic unit, it must be
5th gear
P0658 TCM Actuator supply Power supply REMOVE the mechatronic
voltage A circuit actuators short MIL ON unit. INSPECT and clean
low circuit to ground. TCIL the shift solenoid terminals
ON at the leadframe for metallic
Default contamination.
to 3rd or REINSTALL the
5th gear mechatronic unit.
CONNECT the scan tool
and CLEAR the DTCs.
Road Test the vehicle and
check for DTCs. If the DTC
returns, INSTALL a new
installing the new
calibration.

P0659 TCM Actuator supply Actuator power MIL ON REMOVE the mechatronic
voltage A circuit supply short TCIL unit. INSPECT and clean
high circuit to power ON the shift solenoid terminals
before key ON. Default at the leadframe for metallic
to 3rd or contamination.
5th gear REINSTALL the
mechatronic unit.
and CLEAR the DTCs.
Road Test the vehicle and
installing the new
calibration.
P0667 TCM PCM/ECM/ TCM Substrate CONNECT the scan tool
internal temperature MIL ON and monitor the appropriate
temperature sensor sensor. TCIL PID to verify that an error is
range/performance ON present. REFER to
Default Diagnostic Parameters
to 3rd or Identification (PID) Chart in
5th gear this section. CLEAR the
DTCs. TEST the system for
normal operation. If the
DTC returns, INSTALL a
new mechatronic unit. After
installing the new
calibration.
P0701 Transmission Transmission TCM has Multiple DTC failure with
control control system detected a TCIL conflicting failure mode
system range/performance concern with the ON actions. If other DTCs are
operational One or present, REPAIR them first.
strategy. more CONNECT the scan tool
DTCs set and monitor the appropriate
causing PID to verify that an error is
present. REFER to
transmission
default to Diagnostic Parameters
a Identification (PID) Chart in
hydraulic this section. CLEAR the
limp-homeDTCs. TEST the system for
mode normal operation.
Default REPROGRAM the TCM
to 3rd or first. If the DTC returns,
5th gear INSTALL a new
installing the new
calibration.
P0705

Transmission TR sensor circuit TCM has MIL ON CONNECT the scan tool
Range (TR) error detected a TR TCIL and monitor the appropriate
sensor signal (P, R, N, ON PID to validate that an error
D, 3, 2 or 1) is Default is present. REFER to
out of range. to 3rd or Diagnostic Parameters
5th gear Identification (PID) Chart in
this section. CLEAR the
installing the new
calibration.
P0711 TFT sensor TFT sensor circuit TCM has INSTALL a new
range/performance detected no TFT MIL ON mechatronic unit. After
change during TCIL installing the new
operation. ON mechatronic unit, it must be
5th gear
No TCC
P0712 TFT sensor TFT sensor A TCM has INSTALL a new
circuit low detected a MIL ON mechatronic unit. After
voltage drop TCIL installing the new
across the TFT ON mechatronic unit, it must be
sensor exceeds No TCC programmed with the latest
scale set for calibration.
temperature
(grounded
circuit).
circuit high detected a MIL ON mechatronic unit. After
voltage drop TCIL installing the new
across the TFT ON mechatronic unit, it must be
sensor; exceeds No TCC programmed with the latest
scale set for calibration.
temperature.
circuit intermittent detected no TFT MIL ON mechatronic unit. After
intermittent TCIL installing the new
operation. ON mechatronic unit, it must be
No TCC programmed with the latest
calibration.
P0715 Turbine Shaft TSS sensor A TSS has detected INSTALL a new
Speed (TSS) circuit a short circuit to MIL ON mechatronic unit. After
sensor power. TCIL installing the new
ON mechatronic unit, it must be
No TCC programmed with the latest
engagements
calibration.
Maximum
line

pressure
No
adaptive
learning
strategy
Default
to 3rd
gear
P0716 TSS sensor TSS sensor A TCM has CONNECT the scan tool
circuit detected a loss or MIL ON and monitor the appropriate
range/performance noisy TSS signal TCIL PID to verify that an error is
during operation. ON present. REFER to
No TCC Diagnostic Parameters
MaximumIdentification (PID) Chart in
line this section. CLEAR the
pressure DTCs. TEST the system for
No normal operation. If the
adaptive DTC returns, INSTALL a
learning new mechatronic unit. After
strategy installing the new
Default mechatronic unit, it must be
to 3rd programmed with the latest
gear calibration.
P0717 TSS sensor No TSS sensor A TCM has not CONNECT the scan tool
circuit no signal detected a TSS MIL ON and monitor the appropriate
signal. No TSS TCIL PID to verify that an error is
signal when ON present. REFER to
Output Shaft No TCC Diagnostic Parameters
Speed (OSS) MaximumIdentification (PID) Chart in
signal is present. line this section. CLEAR the
No normal operation. If the
adaptive DTC returns, INSTALL a
learning new mechatronic unit. After
strategy installing the new
Default mechatronic unit, it must be
to 3rd programmed with the latest
gear calibration.
P0720 OSS sensor No OSS sensor TCM has MIL ON INSTALL a new
circuit detected an OSS mechatronic unit. After
short circuit to installing the new
power. mechatronic unit, it must be
calibration.
P0721 OSS sensor OSS sensor circuit TCM has MIL ON CONNECT the scan tool
range/performance detected a loss or and monitor the appropriate
noisy OSS signal PID to verify that an error is
during operation. present. REFER to
Diagnostic Parameters
Identification (PID) Chart in


installing the new
calibration.
P0722 OSS sensor No OSS sensor no TCM has not MIL ON CONNECT the scan tool
signal detected a OSS and monitor the appropriate
signal. No OSS PID to verify that an error is
signal when OSS present. REFER to
signal is present. Diagnostic Parameters
installing the new
calibration.
P0723 OSS sensor No OSS sensor TCM has CONNECT the scan tool
circuit intermittent detected an MIL ON and monitor the appropriate
intermittent TCIL PID to verify that an error is
signal. ON present. REFER to
No TCC Diagnostic Parameters
Hold in Identification (PID) Chart in
gear this section. CLEAR the
currently DTCs. TEST the system for
selected normal operation. If the
MaximumDTC returns, INSTALL a
line new mechatronic unit. After
pressure installing the new
No mechatronic unit, it must be
adaptive programmed with the latest
learning calibration.
strategy
P0729 Transmission Gear 6 incorrect No 6th gear ratio FOLLOW preliminary
ratio detected by the MIL ON diagnostics. CONNECT the
TCM . TCIL scan tool and monitor the
ON appropriate PID to verify
No 6th that an error is present.
gear REFER to Diagnostic
No TCC Parameters Identification
No (PID) Chart in this section.
adaptive CLEAR the DTCs. TEST
learning the system for normal
strategy operation. If the DTC
Maximumreturns, see diagnostic
line Routine 272. REFER to
pressure Diagnosis By Symptom in
Default this section.
to 5th
gear

P0731 Transmission Gear 1 incorrect No 1st gear ratio MIL ON FOLLOW preliminary
ratio detected by the TCIL diagnostics. CONNECT the
TCM . ON scan tool and monitor the
No 1st appropriate PID to verify
gear that an error is present.
No TCC REFER to Diagnostic
No Parameters Identification
adaptive (PID) Chart in this section.
learning CLEAR the DTCs. TEST
strategy the system for normal
Default operation. If the DTC
to 3rd returns, see diagnostic
gear Routine 215. REFER to
MaximumDiagnosis By Symptom in
line this section.
pressure
P0732 Transmission Gear 2 incorrect No 2nd gear ratio FOLLOW preliminary
No TCC that an error is present.
REFER to Diagnostic
engagements
No Parameters Identification
adaptive (PID) Chart in this section.
learning CLEAR the DTCs. TEST
strategy the system for normal
Default operation. If the DTC
to 3rd returns, see diagnostic
gear Routine 220, 224 and 217.
MaximumREFER to Diagnosis By
line Symptom in this section.
pressure
P0733 Transmission Gear 3 incorrect No 3rd gear ratio FOLLOW preliminary
No REFER to Diagnostic
adaptive Parameters Identification
learning (PID) Chart in this section.
strategy CLEAR the DTCs. TEST
Default the system for normal
to 4th operation. If the DTC
gear returns, see diagnostic
MaximumRoutine 221 or 223. REFER
line to Diagnosis By Symptom
pressure in this section.


to 3rd operation. If the DTC
to 3rd operation. If the DTC
P0736 Transmission Reverse incorrect No reverse gear FOLLOW preliminary
ratio ratio detected by MIL ON diagnostics. CONNECT the
the TCM . No TCC scan tool and monitor the
No appropriate PID to verify
adaptive that an error is present.
learning REFER to Diagnostic
strategy Parameters Identification
Default (PID) Chart in this section.
to 4th CLEAR the DTCs. TEST
gear the system for normal
Maximumoperation. If the DTC
line returns, see diagnostic
pressure Routine 202 or 205. REFER
to Diagnosis By Symptom
in this section.
P0740 TCC TCC solenoid TCC solenoid CONNECT the scan tool
solenoid circuit open VFS 6 circuit MIL ON and monitor the TCC PID to
fails. Circuit TCIL verify TCC electrical
open. ON operation. REFER to
No Diagnostic Parameters
adaptive Identification (PID) Chart in
learning this section. CLEAR the
strategy DTCs. TEST the system for
Default normal operation. If the
to 3rd or DTC returns, REMOVE the
5th gear mechatronic unit. INSPECT
No TCC and clean the solenoid
terminals at the leadframe
for metallic contamination.
REINSTALL the
mechatronic unit.


and CLEAR the DTCs.
Road test the vehicle and
installing the new
calibration.
P0741 TCC TCC solenoid TCC solenoid PERFORM normal
circuit performance VFS 6, clutch or MIL ON diagnostics for TCC .
or stuck off circuit open. TCIL FOLLOW diagnostic
ON Routines 240, 241 and 242.
No TCC REFER to Diagnosis By
Symptom in this section.
P0742 TCC TCC solenoid The TCM has CONNECT the scan tool
Solenoid circuit stuck on detected a TCC MIL ON and monitor the TCC PID to
solenoid control TCC is verify TCC electrical
circuit shorted to disabled operation. REFER to
ground. Poor Diagnostic Parameters
launch Identification (PID) Chart in
performance
MaximumDTCs. TEST the system for
line normal operation. If the
pressure DTC returns, REMOVE the
Default mechatronic unit. INSPECT
to 5th and clean the solenoid
gear terminals at the leadframe
DTC for metallic contamination.
P0743 REINSTALL the
may be mechatronic unit.
set CONNECT the scan tool
and CLEAR the DTCs.
installing the new
calibration.
Solenoid circuit electrical detected a TCC TCIL and monitor the TCC PID to
solenoid circuit ON verify TCC electrical
open, shorted to TCC is operation. REFER to
ground or an disabled Diagnostic Parameters
intermittent. MaximumIdentification (PID) Chart in
line this section. CLEAR the
Poor normal operation. If the
launch DTC returns, REMOVE the
mechatronic unit. INSPECT
performance
and clean the solenoid

Default terminals at the leadframe

to 5th for metallic contamination.
gear REINSTALL the
DTCs mechatronic unit.
P0740, CONNECT the scan tool
P0742 or and CLEAR the DTCs.
P0744 Road test the vehicle and
may be check for DTCs. If the DTC
set returns, INSTALL a new
installing the new
calibration.
Solenoid circuit intermittent detected the TCC MIL ON and monitor the TCC PID to
solenoid control TCC is verify TCC electrical
circuit shorted to disabled operation. REFER to
power. DTC Diagnostic Parameters
P0743 Identification (PID) Chart in
may be this section. CLEAR the
set DTCs. TEST the system for
DTC returns, REMOVE the
REINSTALL the
mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P0748 Pressure PCA electrical The TCM will CONNECT the scan tool
Control set this DTC TCIL and monitor the PCA PID to
Solenoid A along with one or ON verify PCA electrical
(PCA) more specific Maximumoperation. REFER to
electrical DTCs. line Diagnostic Parameters
pressure Identification (PID) Chart in
Default this section. CLEAR the
to 5th DTCs. TEST the system for
gear normal operation. If the
DTCs DTC returns, REMOVE the
P0960, mechatronic unit. INSPECT
P0962 or and clean the solenoid
P0963 terminals at the leadframe
may be for metallic contamination.

set REINSTALL the

mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P0750 Shift SSA The TCM has CONNECT the scan tool
Solenoid A detected that the MIL ON and monitor the SSA PID to
(SSA) SSA circuit 5th and verify SSA electrical
failed open or 6th gear operation. REFER to
shorted to power. only Diagnostic Parameters
Poor Identification (PID) Chart in
launch this section. CLEAR the
performanceDTCs. TEST the system for
DTC normal operation. If the
P0753 DTC returns, REMOVE the
may be mechatronic unit. INSPECT
set and clean the shift solenoid
REINSTALL the
mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P0751 SSA SSA The TCM DTC P0751 is a
performance/stuck commanded SSA MIL ON non-electrical DTC. CLEAR
off ON but detected 5th or 6th the DTCs. TEST the system
a ratio error gear only for normal operation. If the
(mechanical Harsh DTC returns, REFER to
failure). reverse Diagnosis By Symptom in
engagement this section.
Neutral
or flair
condition
on
downshift
Poor
launch
performance

DTC
P2700
may be
set
P0752 SSA SSA stuck on The TCM DTC P0752 is a
commanded SSA MIL ON non-electrical DTC. CLEAR
OFF but detected Disable the DTCs. TEST the system
a ratio error 5th and for normal operation. If the
(mechanical 6th gear DTC returns, REFER to
failure). Erratic Diagnosis By Symptom in
shifts this section.
Stuck in
4th gear
DTC
P2700
may be
set
P0753 SSA SSA electrical The TCM will CONNECT the scan tool
set this DTC TCIL and monitor the SSA PID to
along with one or ON verify SSA electrical
more specific 5th and operation. REFER to
electrical DTCs. 6th gear Diagnostic Parameters
only Identification (PID) Chart in
DTCs this section. CLEAR the
P0750, DTCs. TEST the system for
P0973 or normal operation. If the
REINSTALL the
mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P0754 SSA SSA intermittent The TCM will CONNECT the scan tool
set this DTC MIL ON and monitor the SSA PID to
when an Unexpectedverify SSA electrical
intermittent upshifts, operation. REFER to
condition (open, downshifts,Diagnostic Parameters
short to power or flairs or Identification (PID) Chart in
ground) occurs neutral this section. CLEAR the
three times for conditionsDTCs. TEST the system for
less than 5 normal operation. If the
seconds with DTC returns, REMOVE the
each occurrence. mechatronic unit. INSPECT

and clean the shift solenoid

REINSTALL the
mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P0755 Shift SSB The TCM has CONNECT the scan tool
Solenoid B detected that the MIL ON and monitor the SSB PID to
(SSB) SSB circuit has 3rd and verify SSB electrical
failed open or 5th gear operation. REFER to
shorted to power. only Diagnostic Parameters
Harsh Identification (PID) Chart in
1-3 shift this section. CLEAR the
DTC DTCs. TEST the system for
P0758 normal operation. If the
may be DTC returns, REMOVE the
set mechatronic unit. INSPECT
REINSTALL the
mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P0756 SSB SSB The TCM DTC P0756 is a
performance/stuck commanded SSB MIL ON non-electrical DTC. CLEAR
off ON but detected Disable the DTCs. TEST the system
a ratio error 3rd and for normal operation. If the
failure). Neutral Diagnosis By Symptom in
or flair this section.
condition
Transmission
hangs in
2nd on
acceleration

DTC
P2701
may be
set
P0757 SSB SSB stuck on The TCM DTC P0757 is a
commanded SSB MIL ON non-electrical DTC. CLEAR
a ratio error 3rd and for normal operation. If the
condition
Erratic
shifts
DTC
P2701
may set
P0758 SSB SSB electrical The TCM will CONNECT the scan tool
set this DTC TCIL and monitor the SSB PID to
along with one or ON verify SSB electrical
more specific Default operation. REFER to
electrical DTCs. to 3rd or Diagnostic Parameters
5th gear Identification (PID) Chart in
dependingthis section. CLEAR the
on the DTCs. TEST the system for
Minimum DTC returns, REMOVE the
or mechatronic unit. INSPECT
maximum and clean the shift solenoid
line terminals at the leadframe
pressure for metallic contamination.
dependingREINSTALL the
on the mechatronic unit.
DTC CONNECT the scan tool
(failed and CLEAR the DTCs.
voltage Road test the vehicle and
high or check for DTCs. If the DTC
voltage returns, INSTALL a new
low) mechatronic unit. After
DTCs installing the new
P0755, mechatronic unit, it must be
P0976 or programmed with the latest
P0977 calibration.
may be
set
P0759 SSB SSB intermittent The TCM will CONNECT the scan tool
set this DTC MIL ON and monitor the SSB PID to
when an Unexpectedverify SSB electrical


REINSTALL the
mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P0760 Shift SSC The TCM CONNECT the scan tool
Solenoid C detected that he MIL ON and monitor the SSC PID to
(SSC) SSC circuit Disable verify SSC electrical
failed open. 2nd and operation. REFER to
6th gear Diagnostic Parameters
Erratic or Identification (PID) Chart in
harsh 1-3 this section. CLEAR the
shift DTCs. TEST the system for
REINSTALL the
mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P0761 SSC SSC The TCM DTC P0761 is a
performance/stuck commanded SSC MIL ON non-electrical DTC. CLEAR
off ON but detected Disable the DTCs. TEST the system
a ratio error 2nd and for normal operation. If the
condition
DTC
P2702
may be

set
P0762 SSC SSC stuck on The TCM DTC P0762 is a
commanded SSC MIL ON non-electrical DTC. CLEAR
OFF but detected 2nd and the DTCs. TEST the system
a ratio error 6th gear for normal operation. If the
(mechanical only DTC returns, REFER to
failure). Harsh Diagnosis By Symptom in
reverse this section.
engagement
Erratic
shift or
stuck in
6th
DTC
P2702
may be
set
P0763 SSC SSC electrical The TCM will CONNECT the scan tool
set this DTC TCIL and monitor the SSC PID to
along with one or ON verify SSC electrical
more specific Default operation. REFER to
electrical DTCs. to 2nd Diagnostic Parameters
and 6th Identification (PID) Chart in
gear or this section. CLEAR the
1st and DTCs. TEST the system for
3rd normal operation. If the
dependingDTC returns, REMOVE the
on the mechatronic unit. INSPECT
DTC and clean the shift solenoid
Minimum terminals at the leadframe
or for metallic contamination.
maximum REINSTALL the
line mechatronic unit.
pressure CONNECT the scan tool
dependingand CLEAR the DTCs.
on the Road test the vehicle and
DTC check for DTCs. If the DTC
(failed returns, INSTALL a new
voltage mechatronic unit. After
high or installing the new
voltage mechatronic unit, it must be
low) programmed with the latest
DTCs calibration.
P0760,
P0979 or
P0980
may be
set
P0764 SSC SSC intermittent The TCM will CONNECT the scan tool
set this DTC MIL ON and monitor the SSC PID to
when an Unexpectedverify SSC electrical


REINSTALL the
mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P0765 Shift SSD The TCM CONNECT the scan tool
Solenoid D detected that the MIL ON and monitor the SSD PID to
(SSD) SSD circuit TCIL verify SSD electrical
failed open. ON operation. REFER to
Disable Diagnostic Parameters
1st gear Identification (PID) Chart in
DTC this section. CLEAR the
P0768 DTCs. TEST the system for
may be normal operation. If the
set DTC returns, REMOVE the
REINSTALL the
mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P0766 SSD SSD The TCM DTC P0766 is a
performance/stuck commanded SSD MIL ON non-electrical DTC. CLEAR
off ON but detected 2nd and the DTCs. TEST the system
a ratio error 3rd gear for normal operation. If the
(mechanical only DTC returns, REFER to
failure). Delayed Diagnosis By Symptom in
or no this section.
reverse

engagement
DTC
P2703
and/or
DTC
P2704
may be
set
P0767 SSD SSD stuck on The TCM DTC P0767 is a
commanded SSD MIL ON non-electrical DTC. CLEAR
OFF but detected 4th gear the DTCs. TEST the system
a ratio error only for normal operation. If the
(mechanical DTC DTC returns, REFER to
failure). P2704 Diagnosis By Symptom in
may be this section.
set
P0768 SSD SSD electrical The TCM will CONNECT the scan tool
set this DTC TCIL and monitor the SSD PID to
along with one or ON verify SSD electrical
more specific Disable operation. REFER to
electrical DTCs. 1st gear Diagnostic Parameters
or 3rd Identification (PID) Chart in
gear only this section. CLEAR the
dependingDTCs. TEST the system for
on the normal operation. If the
DTC DTC returns, REMOVE the
Minimum mechatronic unit. INSPECT
or and clean the shift solenoid
maximum terminals at the leadframe
line for metallic contamination.
pressure REINSTALL the
dependingmechatronic unit.
on the CONNECT the scan tool
DTC and CLEAR the DTCs.
(failed Road test the vehicle and
voltage check for DTCs. If the DTC
high or returns, INSTALL a new
voltage mechatronic unit. After
low) installing the new
DTCs mechatronic unit, it must be
P0765, programmed with the latest
P0982 or calibration.
P0983
may be
set
P0769 SSD SSD intermittent The TCM will CONNECT the scan tool
set this DTC MIL ON and monitor the SSD PID to
when an Unexpectedverify SSD electrical


REINSTALL the
mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P0770 Shift SSE SSE circuit or CONNECT the scan tool
Solenoid E solenoid failure. MIL ON and monitor the SSE PID to
(SSE) TCIL verify SSE electrical
ON operation. REFER to
MEASURE the resistance of
SSE . If the value is not
between 9.5 to 10.5 ohms,
INSTALL a new SSE ,
REFER to Mechatronic
Assembly in this section. If
the value is between 9.5 to
10.5 ohms, REINSTALL
the mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P0771 SSE SSE The TCM DTC P0771 is a
performance/stuck commanded SSE MIL ON non-electrical DTC. CLEAR
off ON but detected 1st, 2nd the DTCs. TEST the system
a ratio error and 3rd for normal operation. If the

(mechanical gear only DTC returns, REFER to

failure). Erratic Diagnosis By Symptom in
shifting, this section.
flairs or
neutral
condition
DTC
P0984
may be
set
P0772 SSE SSE stuck on The TCM DTC P0772 is a
commanded SSE MIL ON non-electrical DTC. CLEAR
a ratio error 1st, 2nd for normal operation. If the
(mechanical and 3rd DTC returns, REFER to
failure). gear Diagnosis By Symptom in
4th gear this section.
launch
DTC
P0984
may be
set
P0773 SSE SSE electrical The TCM will CONNECT the scan tool
set this DTC MIL ON and monitor the SSE PID to
along with one or TCIL verify SSE electrical
more specific ON operation. REFER to
electrical DTCs. Default Diagnostic Parameters
DTC DTCs. TEST the system for
P0770 normal operation. If the
may be DTC returns, REMOVE the
set mechatronic unit. INSPECT
INSTALL a new SSE ,
and CLEAR the DTCs.
installing the new

calibration.
P0774 SSE SSE intermittent The TCM will CONNECT the scan tool
set this DTC TCIL and monitor the SSE PID to
when an ON verify SSE electrical
intermittent Hangs In operation. REFER to
condition (open, 1st gear Diagnostic Parameters
short to power or Default Identification (PID) Chart in
ground) occurs to 3rd or this section. CLEAR the
three times for 5th gear DTCs. TEST the system for
less than 5 DTC normal operation. If the
seconds with P0770 DTC returns, REMOVE the
each occurrence. may be mechatronic unit. INSPECT
INSTALL a new SSE ,
and CLEAR the DTCs.
installing the new
calibration.
P07A8 Friction Friction element D The DTC P07A8 is a
Element D performance/stuck Low/Reverse Disable non-electrical DTC. CLEAR
off clutch failed off, 1st gear the DTCs. TEST the system
ratio error Delayed for normal operation. If the
(mechanical or no DTC returns, REFER to
failure) reverse Diagnosis By Symptom in
engagementthis section.
P07A9 Friction Friction element D The DTC P07A9 is a
Element D stuck on Low/Reverse 1st gear non-electrical DTC. CLEAR
clutch failed on, only the DTCs. TEST the system
ratio error High for normal operation. If the
(mechanical engine DTC returns, REFER to
failure) rpm Diagnosis By Symptom in
this section.
P07AA Friction Friction element E Clutch 4, 5, 6 DTC P07AA is a
Element E performance/stuck failed off, ratio Disable non-electrical DTC. CLEAR
off error 4th, 5th the DTCs. TEST the system
(mechanical and 6th for normal operation. If the
failure) gear DTC returns, REFER to

Erratic Diagnosis By Symptom in

shifts, this section.
neutral
conditions,
flair or
high
engine
rpm
P0781 Transmission 1-2 or 2-1 shift Incorrect ratio CONNECT the scan tool
error calculated during Incorrect and monitor the appropriate
shift 1-2 or 2-1. gear PID to verify that an error is
selection present. REFER to
dependingDiagnostic Parameters
on failure Identification (PID) Chart in
or mode this section. CLEAR the
and DTCs. TEST the system for
manual normal operation. If the
lever DTC returns, see diagnostic
position. Routine 220 or 225. REFER
Shift to Diagnosis By Symptom
errors in this section.
may also
be due to
other
internal
transmission
concerns
(stuck
valves,
damaged
friction
material)
MIL ON
TCIL
ON
No TCC
No
adaptive
learning
strategy
Hold in
3rd, 2nd
or 4th
gear
shift 2-3. gear PID to verify that an error is


may also
be due to
other
internal
transmission
concerns
(stuck
valves,
damaged
friction
material)
MIL ON
TCIL
ON
No TCC
No
adaptive
learning
strategy
Hold in
4th, 3rd
or 2nd
gear
may also
be due to
other
internal
transmission
concerns
(stuck
valves,
damaged
friction
material)
MIL ON
TCIL
ON
No TCC

No
adaptive
learning
strategy
Default
to 3rd or
4th gear
may also
be due to
other
internal
transmission
concerns
(stuck
valves,
damaged
friction
material)
MIL ON
TCIL
ON
No TCC
No
adaptive
learning
strategy
Default
to 4th or
5th gear


may also
be due to
other
internal
transmission
concerns
(stuck
valves,
damaged
friction
material)
MIL ON
TCIL
ON
No TCC
Default
to 2nd or
3rd gear
P0960 Pressure PCA control circuit PCA circuit CONNECT the scan tool
Control open failed during MIL ON and monitor the PCA PID to
Solenoid A operation. TCIL verify PCA electrical
(PCA) ON operation. REFER to
No Diagnostic Parameters
adaptive Identification (PID) Chart in
strategy this section. CLEAR the
MaximumDTCs. TEST the system for
line normal operation. If the
pressure DTC returns, REMOVE the
REINSTALL the
mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P0962 PCA PCA control circuit Voltage through CONNECT the scan tool
low PCA was not MIL ON and monitor the PCA PID to
detected when TCIL verify PCA electrical
the solenoid was ON operation. REFER to
commanded on. Default Diagnostic Parameters


REINSTALL the
mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P0963 PCA PCA circuit high Voltage through CONNECT the scan tool
PCA was not MIL ON and monitor the PCA PID to
detected when TCIL verify PCA electrical
commanded on. MaximumDiagnostic Parameters
line Identification (PID) Chart in
pressure this section. CLEAR the
No DTCs. TEST the system for
adaptive normal operation. If the
strategy DTC returns, REMOVE the
REINSTALL the
mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P0972 Shift SSA control circuit SSA control CONNECT the scan tool
Solenoid A range/performance circuit or MIL ON and monitor the SSA PID to
(SSA) solenoid failure. TCIL verify SSA electrical


REINSTALL the
mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P0973 SSA SSA control circuit Voltage through CONNECT the scan tool
low SSA was not MIL ON and monitor the SSA PID to
detected when TCIL verify SSA electrical
commanded off. Default Diagnostic Parameters
Short to ground to 3rd or Identification (PID) Chart in
detected. 5th gear this section. CLEAR the
REINSTALL the
mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P0974 SSA SSA control circuit Voltage through CONNECT the scan tool
high SSA was not MIL ON and monitor the SSA PID to
detected when TCIL verify SSA electrical
Open or short to to 3rd or Identification (PID) Chart in
power detected. 5th gear this section. CLEAR the


REINSTALL the
mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P0975 Shift SSB control circuit SSB control CONNECT the scan tool
Solenoid B range/performance circuit or MIL ON and monitor the SSB PID to
(SSB) solenoid failure. TCIL verify SSB electrical
REINSTALL the
mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P0976 SSB SSB circuit low Voltage through CONNECT the scan tool
SSB was not MIL ON and monitor the SSB PID to
detected when TCIL verify SSB electrical
REINSTALL the

mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P0977 SSB SSB circuit high Voltage through CONNECT the scan tool
SSB was not MIL ON and monitor the SSB PID to
detected when TCIL verify SSB electrical
REINSTALL the
mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P0978 Shift SSC control circuit SSC control CONNECT the scan tool
Solenoid C range/performance circuit or MIL ON and monitor the SSC PID to
(SSC) solenoid failure. TCIL verify SSC electrical
REINSTALL the
mechatronic unit.

and CLEAR the DTCs.

installing the new
calibration.
P0979 SSC SSC control circuit Voltage through CONNECT the scan tool
low SSC was not MIL ON and monitor the SSC PID to
detected when TCIL verify SSC electrical
REINSTALL the
mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P0980 SSC SSC control circuit Voltage through CONNECT the scan tool
high SSC was not MIL ON and monitor the SSC PID to
detected when TCIL verify SSC electrical
REINSTALL the
mechatronic unit.
and CLEAR the DTCs.


installing the new
calibration.
P0981 Shift SSD control circuit SSD control CONNECT the scan tool
Solenoid D range/performance circuit or MIL ON and monitor the SSD PID to
(SSD) solenoid failure. TCIL verify SSD electrical
REINSTALL the
mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P0982 SSD SSD control circuit Voltage through CONNECT the scan tool
low SSD was not MIL ON and monitor the SSD PID to
detected when TCIL verify SSD electrical
REINSTALL the
mechatronic unit.
and CLEAR the DTCs.


installing the new
calibration.
P0983 SSD SSD control circuit Voltage through CONNECT the scan tool
high SSD was not MIL ON and monitor the SSD PID to
detected when TCIL verify SSD electrical
REINSTALL the
mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P0985 SSE SSE control circuit Voltage through CONNECT the scan tool
low SSE was not MIL ON and monitor the SSE PID to
detected when TCIL verify SSE electrical
INSTALL a new SSE ,


and CLEAR the DTCs.
installing the new
calibration.
P0986 SSE SSE control circuit Voltage through CONNECT the scan tool
high SSE was not MIL ON and monitor the SSE PID to
detected when TCIL verify SSE electrical
INSTALL a new SSE ,
and CLEAR the DTCs.
installing the new
calibration.
P1705 TR sensor TR circuit not TR circuit not - VERIFY the selector lever
indicating indicating is in PARK or NEUTRAL.
park/neutral during park/neutral CLEAR the DTC. RERUN
self-test during Key ON the KOEO and/or KO
Engine OFF self-test. TEST the system
(KOEO) or Key for normal operation.
ON Engine
Running
(KOER)
self-test.
P1707 Transmission

Park/Neutral (P/N) Circuit or sensor Engine CONNECT the scan tool

switch circuit failure high. will not and monitor the appropriate
failure crank in PID to verify that an error is
Circuit or sensor P or N or present. REFER to
failure low. engine Diagnostic Parameters
will Identification (PID) Chart in
crank in this section. CLEAR the
all gears DTCs. TEST the system for
TCIL normal operation. CHECK
ON the shift linkage. If the DTC
installing the new
calibration.
P1910 Reverse lamp Reverse lamp Control circuit or CONNECT the scan tool
circuit control circuit open sensor failure. Park lock and monitor the appropriate
or PID to verify that an error is
interlock present. REFER to
switched Diagnostic Parameters
OFF Identification (PID) Chart in
Reverse this section. CLEAR the
lamps DTCs. TEST system for
may be normal operation. If DTC
on at all returns, REFER to Section
times 417-01 .
Reverse
may not
come on
P1911 Reverse lamp Reverse lamp Circuit or sensor - CONNECT the scan tool
circuit control circuit failure. and monitor the appropriate
shorted to ground. PID to verify that an error is
Circuit low present. REFER to
Diagnostic Parameters
DTCs. TEST system for
normal operation. If DTC
returns, REFER to Section
417-01 .
P1912 Reverse Reverse lamp Circuit or sensor CONNECT the scan tool
lampircuit control circuit failure. Park lock and monitor the appropriate
shorted to power. or PID to verify that an error is
Circuit high interlock present. REFER to
switched Diagnostic Parameters
OFF Identification (PID) Chart in
DTCs. TEST system for
normal operation. If DTC
returns, REFER to Section
417-01 .
P2763 TCC

TCC pressure Voltage through MIL ON CONNECT the scan tool

control solenoid TCC was not TCIL and monitor the TCC PID to
control circuit high. detected when ON verify TCC electrical
the solenoid was No TCC operation. REFER to
commanded on. No Diagnostic Parameters
Short to power adaptive Identification (PID) Chart in
detected. learning this section. CLEAR the
strategy DTCs. TEST the system for
Default normal operation. If the
to 3rd or DTC returns, REMOVE the
5th gear mechatronic unit. INSPECT
REINSTALL the
mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P2764 TCC TCC pressure TCC was not CONNECT the scan tool
control solenoid detected when MIL ON and monitor the TCC PID to
control circuit low. the solenoid was TCIL verify TCC electrical
commanded on. ON operation. REFER to
Short to ground No TCC Diagnostic Parameters
detected. No Identification (PID) Chart in
adaptive this section. CLEAR the
learn DTCs. TEST the system for
strategy normal operation. If the
REINSTALL the
mechatronic unit.
and CLEAR the DTCs.
installing the new
calibration.
P062F TCM Internal control Internal TCM CLEAR the DTCs. TEST
module EEPROM with Electrically MIL ON the system for normal

error Erasable Mechanicaloperation. If the DTC

Programmable limp-homereturns, install a new
Read-Only mode mechatronic unit. After
Memory installing the new
(EEPROM) mechatronic unit, it must be
error. programmed with the latest
calibration.
U0073 Controller Control module CAN REFER to Powertrain
Area communication bus communication TCIL Control/Emissions
Network off bus off, short ON Diagnosis (PC/ED) manual.
(CAN) circuit CAN high No TCC
to CAN low. No
adaptive
learn
strategy
Default
to 3rd
gear
Maximum
line
pressure
U0100 CAN Lost CAN link error REFER to Powertrain
communication detected by TCM TCIL Control/Emissions
with ECM/PCM A , between TCM ON Diagnosis (PC/ED) manual.
and PCM. No TCC
No
adaptive
learn
strategy
Default
to 3rd
gear
Maximum
line
pressure
U0155 CAN Lost CAN link error REFER to Powertrain
communication detected by the No Control/Emissions
with Instrument TCM and IC . communication
Cluster (IC) control with the
module IC



6R80 Manual
Transmission Connector Layouts
Transmission Vehicle Harness - C1548
Pin Number Circuit Function

1 Tow/Haul switch signal
2 Controller Area Network (CAN) low
3 NOT USED
4 NOT USED
5 NOT USED
6 CAN high
7 Reverse lamp relay power
8 NOT USED
9 Ignition voltage
10 Park/Neutral signal
11 NOT USED
12 NOT USED
13 Ground
14 Battery voltage
15 Reverse lamp relay ground
16 Ground
Transmission Connector Layouts 2541

Transmission Vehicle Harness - C1548 2542


6R80 Manual
Pinpoint Tests - OSC Equipped Vehicle
Special Tool(s)


Any time an electrical connector is disconnected, inspect the connector terminal condition for corrosion and
contamination. Also inspconnector seal for damage. Clean, repair or install a new component as required.
Pinpoint Test
Refer to Wiring Diagrams Cell 29 , Transmission Controls for schematic and connector information.
PINPOINT TEST A: SYSTEM VOLTAGE LOW
NOTE: Refer to Transmission Vehicle Harness illustration within the Transmission Connector Layouts
procedure in this section.
NOTE: Read and record all DTCs.

A1 CHECK FOR DTCs
Yes
Connect the scan tool. GO to A2 .
Ignition ON.
Check for DTC P0562. No
Is DTC P0562 set? REFER to Section 414-00 .
A2 CHECK BATTERY VOLTAGE
Yes
Measure the voltage across the GO to A3 .
battery terminals. Record the
measurement. No
Pinpoint Tests - OSC Equipped Vehicle 2543

Is the voltage greater than 10.5

volts?
A3 CHECK CHARGING SYSTEM
Yes
Start the engine. GO to A4 .
Bring the engine up to normal
operating temperature and allow the No
engine to idle. REFER to Section 414-00 .
Is the generator/check engine lamp
off?
A4 CHECK CHARGING SYSTEM
Yes
With the engine running, increase the
engine speed to 2,000 rpm and No
observe the scan tool VPWR TCM REFER to Section 414-00 .
PID.
Is the system voltage between 13
volts and 15 volts?
A5 CHECK CIRCUIT CBB55 (VT/OG)
FOR BATTERY VOLTAGE
Yes
Ignition OFF. REPLACE the mechatronic assembly. REFER to
Disconnect: Transmission C1548. Mechatronic Assembly in this section. Program the
Measure the voltage between mechatronic assembly with the latest calibration. CLEAR
transmission C1548-9, circuit CBB55 all DTCs. TEST the system for normal operation.
No
REMOVE and INSPECT fuse 54 (5A). If the fuse is
blown, REPAIR circuit CBB55 (VT/OG) for a short to
ground. If the fuse is good, REPAIR circuit CBB55
(VT/OG) for an open. CLEAR the DTC. TEST the system
Is the voltage greater than 10.5

volts?
PINPOINT TEST A: SYSTEM VOLTAGE LOW 2544

PINPOINT TEST A: SYSTEM VOLTAGE LOW 2545


6R80 Manual
Special Testing Procedures
The special tests are designed to aid the technician in diagnosing the hydraulic and mechanical portions of the
transmission.
Air Pressure Test
Item Deption
1 Intermediate clutch (C) port
2 Low/reverse clutch (D1) port
3 Not used
4 Direct clutch (B) port
5 Overdrive clutch (E) port
6 Forward clutch (A) port
7 Thermal bypass valve
A no-drive condition can exist with correct transmission fluid pressure because of inoperative clutches. Refer
to the Clutch Application Chart to determine the appropriate elements. A clutch concern can be located
through a series of checks by substituting air pressure for fluid pressure to determine the location of the
concern.
Example: When the selector lever is in a forward gear range, a no-drive condition may be caused by an
inoperative clutch.
1. Drain the transmission fluid. Remove the transmission fluid pan.
2. Remove the transmission fluid filter, seal assembly and mechatronic unit.
3. Locate the inoperative clutches by applying air pressure into the appropriate clutch port.
Special Testing Procedures 2546

4. Apply air pressure to the appropriate clutch port. A dull thud may be heard or movement felt when a
clutch piston is applied. If the clutch seals or check ball are leaking, a hissing sound may be heard.
5. If the clutches fail to operate during the air check:

the piston seals are not seated, damaged or installed incorrectly.
plugged feed holes for clutch apply in the case and/or clutch cylinder.
damaged piston and/or clutch cylinder.
6. Service as required and recheck.
Special Testing Procedures 2547


6R80 Manual
Leakage Inspection
Special Tool(s)
Leak Tester, Torque Converter

307-691
Material
Item Specification
Dye-Lite ATF/Power Steering Fluid -
Leak Detection
164-R3701 (Rotunda)
Leak Check Test
NOTE: When diagnosing transmission leaks, the source of the leak must be positively identified prior to
repair. If the vehicle is driven extensively between adding the fluorescent additive and performing the leak
test, the leaking oil can spread and make identifying the location of the leak difficult.
1. Clean off any transmission fluid from the top and bottom of the torque converter housing, the front of
the case and rear face of the engine and oil pan. Clean the torque converter area by washing with a
nonflammable solvent and blow dry with compressed air.
2. Add Dye-Lite ATF Power Steering Fluid Leak Detection Dye to the transmission fluid. Use one 30
ml (1 fl. oz) of dye solution for every 3.8 L (4 qt) of transmission fluid.
3. Start and run the engine until the transmission reaches its normal operating temperature. Raise the
vehicle on a hoist and run the engine occasionally shifting to the DRIVE and REVERSE ranges to
increase pressure within the transmission. Using a black light, observe the back of the cylinder block
and top of the torque converter housing for evidence of fluid leakage. Run the engine until
transmission fluid leakage is evident and the probable source of leakage can be determined.
4. If the source of the leak is obvious, repair as required. Leaks from the torque converter housing can
originate from several locations. The paths which the fluid takes to reach the bottom of the torque
converter hous are shown in the illustration. The 5 steps following correspond with the numbers in the
illustration.
1. Transmission fluid leaking by the converter hub seal lip will tend to move along the drive hub
and onto the back of the torque converter. Except in the case of a total seal failure,
Leakage Inspection 2548

transmission fluid leakage by the lip of the seal will be deposited on the inside of the torque
converter housing only, near the outside diameter of the housing.
2. Transmission fluid leakage by the outside diameter of the converter impeller hub seal and the
case will follow the same path that leaks by the ID of the converter hub seal follow.
3. Transmission fluid leakage from the converter cover weld or the converter-to-flexplate stud
weld will appear at outside diameter of torque converter on the back face of the flexplate and
in the converter housing only near the flexplate. If a converter-to-flexplate lug, lug weld or
converter cover weld leak is suspected, remove the converter and pressure check.
4. Transmission fluid leakage from the bolts inside the converter housing will flow down the
back of the torque converter housing. Leakage may be from loose or missing bolts.
5. Engine oil leaks from the rear main oil.
5. Remove the torque converter.
6. Using a black light, observe the torque converter housing. Inspect for evidence of dye from the pump
bolts, pump seal, and torque converter hub seal. Repair as required.
7. If the source of the leak is not evident, continue with this procedure to leak test the torque converter.
8. Install the torque converter in the arbor press. Support the torque converter on the mounting pads.
9. Install the Leak Tester, Torque Converter 307-691 into the torque converter hub. Tighten to 25 Nm.
10. Secure the press. Only apply enough force from the press to seal the Leak Tester, Torque Converter
307-691 into the torque converter hub.
11. Connect a compressed air supply to the Leak Tester, Torque Converter 307-691.

12. With air pressure applied to valve, inspect for leaks at the converter hub weld and seams. A soap
bubble solution can be applied around those areas to aid in the diagnosis. If any leaks are present,
install a new torque converter.
13. With air pressure applied to valve, inspect for leaks at the stud or mounting pad and balance weight
welds. A soap bubble solution can be applied around those areas to aid in the diagnosis. If any leaks
are present, install a new torque converter.
14. After leaks are repaired, clean the remaining transmission fluid dye from serviced areas.


6R80 Manual
Transmission Fluid Cooler
NOTICE: If the transmission is disassembled to install new parts, backflush and clean the transmission
fluid cooler and transmission fluid cooler tubes.
NOTE: Cleaning and backflushing the transmission fluid cooling system, along with following all the normal
cleaning and inspection procedures during disassembly and reassembly, keeps contaminants from entering the
transmission, causing a repeat repair.
When internal wear or damage has occurred in the transmission, metal particles or clutch plate material may
have been carried into the torque converter and transmission fluid cooler. These contaminants are a major
cause of recurring transmission troubles and must be removed from the system before the transmission is put
back into use. For backflushing and cleaning procedures, refer to Transmission Fluid Cooler Backflushing and
Cleaning in this section.
Transmission Fluid Cooler 2551

SECTION 307-01: Automatic Transaxle/Transmission 2011 Expedition, Navigator Workshop

6R80 Manual
Diagnosis By Symptom
The Diagnosis By Symptom gives the technician diagnostic information and direction, and suggests possible
components using a symptom as a starting point. All routines start out with any potential electrical
components that can cause or contribute to the symptom described. The routines then list all possible
hydraulic or mechanical components that can cause or contribute the symptom described.
Diagnosis by Symptom Chart Directions
1. Using the Diagnosis by Symptom, select the condition that best describes the condition.
2. Refer to the Routine indicated in the Diagnosis by Symptom Index.
3. Always begin diagnosis of a symptom with:

1. preliminary inspections.
2. verifications of condition.
3. checking the fluid levels.
4. perform other test procedures as directed.
4. NOTE: Not all concerns and conditions with electrical components will set a DTC. Be aware that
components listed may still be the cause. Verify correct function of these components prior to
proceeding to the Hydraulic/Mechanical Routine listed.
NOTE: When the battery is disconnected or a new battery is installed, certain transmission operating
parameters can be lost. The Transmission Control Module (TCM) must relearn these parameters.
During this learning process, slightly firm shifts, delayed or early shifts may occur. This operation is
considered normal and will not affect the function of the transmission. Normal operation will return
once these parameters are stored in the TCM .
Begin with the ROUTINES, if indicated. Follow the reference or action required statements. Always
perform the On-Board Diagnostic (OBD) tests as required. Never skip steps. Repair as required. If the
concern is still present after electrical diagnosis, proceed to the Hydraulic/Mechanical Routine listed.
5. The list contains only possible hydraulic or mechanical components that may cause or contribute to
the concern. These components are listed in the removal sequence and by most probable cause. All
components listed must be inspected to make sure that repairs are complete.
Diagnosis by Symptom Index
Title Routines
Engagement Concerns
No Forward In Drive 201
No Reverse 202
Harsh Reverse 203
Harsh Forward 204
Diagnosis By Symptom 2552

Delayed/Soft Reverse 205

Delayed/Soft Forward 206
No Forward and No Reverse 207
Harsh Forward and Harsh Reverse 208
Delayed Forward and Delayed Reverse 209
Shift Concerns
Some/All Shifts Missing 210
Timing Early/Late 211
Timing Erratic/Hunting 212
Feel Concerns
Soft/Slipping (some or all) 213
Harsh (some or all) 214
No 1st Gear, Engages in Higher Gear 215
No Manual 1st Gear 216
No Manual 2nd Gear 217
No Manual 3rd Gear 218
No 1-2 Shift 220
No 2-3 Shift 221
No 3-4 Shift 222
No 4-5 Shift 270
No 5-6 Shift 272
No 6-5 Shift 273
No 5-4 Shift 271
No 4-3 Shift 223
No 3-2 Shift 224
No 2-1 Shift 225
Torque Converter Operation Concerns
No Apply 240
Cycling/Chatter 241
Always Applied/Stalls Vehicle 242
Other Concerns
External Leaks 252
Noise/Vibration in Forward or Reverse 254
Engine Will Not Crank 255
No Park (P) Range 256
Transmission Overheating 257
Fluid Venting/Foaming 261
Diagnostic Routines
Engagement Concerns: No Forward in Drive
Possible
Component Reference/Action

201 ROUTINE
Transmission
Fluid
Incorrect CHECK the transmission fluid level. ADJUST transmission fluid to correct
level level. REFER to Transmission Fluid Level Check in this section.
Selector Lever
Linkage
Selector INSPECT and REPAIR as required. VERIFY selector lever cable adjustment.
lever REFER to Section 307-05 . ADJUST selector lever cable as necessary.
linkage

damage or
incorrectly
adjusted
Mechatronics
Electronic REMOVE the mechatronic unit. INSPECT and CLEAN the shift solenoid
component terminals on the mechatronic leadframe for metallic contamination. INSTALL
the mechatronic unit. REFER to Mechatronic Assembly in this section.
failure CONNECT the scan tool and CLEAR the DTCs. ROAD TEST the vehicle and
check for DTCs. If the DTC returns, install a new mechatronic unit. REFER to
Mechatronic Assembly in this section. After installing the new mechatronic
unit, it must be programmed with the latest calibration.
Defective INSPECT and CLEAN the SSA terminals on the mechatronic leadframe for
Shift metallic contamination. REFER to Mechatronic Assembly in this section.
Solenoid CONNECT the scan tool and CLEAR the DTCs. ROAD TEST the vehicle and
A (SSA) check for DTCs. If the DTC returns, install a new mechatronic unit. REFER to
Defective Inspect manual valve linkage.

manual
valve
Defective INSPECT mechatronic assembly for stuck valves or contamination. REFER to

clutch A Mechatronic Assembly in this section.
regulator
valve
Clutch Plates
Forward INSPECT the forward clutch assembly for damage. REPAIR as required.
clutch (A) REFER to Forward Clutch Assembly in this section.
friction
and steel
plate
failure

Direct INSPECT the direct clutch assembly for damage. REPAIR as required. REFER
clutch (B) to Direct Clutch Assembly in this section.
friction
and steel
plate
failure
Low/reverse INSPECT the low/reverse clutch assembly for damage. REPAIR as required.
clutch (D) REFER to Low/Reverse Clutch Assembly in this section.
friction
and steel
plate
failure
Pump
Pump gear INSTALL a new pump assembly. REFER to Pump Assembly in this section.

failure
Engagement Concerns: No Reverse
Possible Component Reference/Action

202 ROUTINE
Transmission Fluid
Selector Lever
Linkage
Selector INSPECT and REPAIR as required. VERIFY selector lever cable adjustment.
lever REFER to Section 307-05 . ADJUST selector lever cable as necessary.
linkage
damage or
incorrectly
adjusted
Mechatronics
failure the mechatronic unit. REFER to Mechatronic Assembly in this section.
CONNECT the scan tool and clear the DTCs. ROAD TEST the vehicle and
Defective INSPECT and CLEAN the SSB terminals on the mechatronic leadframe for

Solenoid B CONNECT the scan tool and clear the DTCs. ROAD TEST the vehicle and
(SSB) check for DTCs. If the DTC returns, install a new mechatronic unit. REFER to

direct Mechatronic Assembly in this section.
clutch (B)
or
low/reverse
clutch (D)
regulator
valve
Clutch Plates
Direct INSPECT the direct clutch assembly for damage. REPAIR as required.
clutch (B) REFER to Direct Clutch Assembly in this section.
friction and
steel plate
failure
Pump
Pump gear INSTALL a new pump assembly. REFER to Pump Assembly in this section.
failure
Engagement Concerns: Harsh Reverse

203 ROUTINE
Transmission Fluid
Incorrect level CHECK the transmission fluid level. ADJUST transmission

fluid to correct level. REFER to Transmission Fluid Level
Mechatronics
Electronic REMOVE the mechatronic unit. INSPECT and CLEAN the shift
component solenoid terminals on the mechatronic leadframe for metallic
failure contamination. INSTALL the mechatronic unit. REFER to
Mechatronic Assembly in this section. CONNECT the scan tool
and clear the DTCs. ROAD TEST the vehicle and check for
DTCs. If the DTC returns, install a new mechatronic unit.
REFER to Mechatronic Assembly in this section. After
installing the new mechatronic unit, it must be programmed with
Defective Shift INSPECT and CLEAN the SSB terminals on the mechatronic
Solenoid B (SSB) leadframe for metallic contamination. REFER to Mechatronic

Assembly in this section. CONNECT the scan tool and clear the
DTCs. ROAD TEST the vehicle and check for DTCs. If the
DTC returns, install a new mechatronic unit. REFER to
Mechatronic Assembly in this section. After installing the new
mechatronic unit, it must be programmed with the latest
calibration.
Defective clutch B INSPECT mechatronic assembly for stuck valves or

regulator valve contamination. REFER to Mechatronic Assembly in this section.
Transmission INSTALL a new mechatronic assembly. REFER to Mechatronic

Control Module Assembly in this section.
(TCM)
mechatronic unit
failed
Driveline
Engine driveline INSPECT and REPAIR as required.

looseness in the
driveshaft, U-joints
or the engine
mounts
Engagement Concerns: Harsh Forward

204 ROUTINE
Transmission Fluid
Mechatronics
component terminals on the mechatronic leadframe for metallic contamination.
failure INSTALL the mechatronic unit. REFER to Mechatronic Assembly in this
section. CONNECT the scan tool and clear the DTCs. ROAD TEST the
vehicle and check for DTCs. If the DTC returns, install a new mechatronic
unit. REFER to Mechatronic Assembly in this section. After installing the
new mechatronic unit, it must be programmed with the latest calibration.
Solenoid A CONNECT the scan tool and clear the DTCs. ROAD TEST the vehicle and
(SSA) check for DTCs. If the DTC returns, install a new mechatronic unit. REFER
to Mechatronic Assembly in this section. After installing the new
mechatronic unit, it must be programmed with the latest calibration.

Defective INSPECT mechatronic assembly for stuck valves or contamination. REFER

clutch A to Mechatronic Assembly in this section.
regulator
valve

latch valve
TCM INSTALL a new mechatronic assembly. REFER to Mechatronic Assembly

mechatronic in this section.
unit
failed
Driveline
Engine INSPECT and REPAIR as required.

driveline
looseness in
the
driveshaft,
U-joints or
the engine
mounts
Engagement Concerns: Delayed/Soft Reverse

205 ROUTINE
Transmission Fluid
Transmission INSTALL a new transmission fluid filter assembly. REFER to Fluid Pan,
fluid filter Gasket and Filter in this section.
and seal
assembly

plugged,
damaged
Mechatronics
check for DTCs. If the DTC returns, install a new mechatronic unit. REFER
to Mechatronic Assembly in this section. After installing the new mechatronic

(SSB) check for DTCs. If the DTC returns, install a new mechatronic unit. REFER

clutch B to Mechatronic Assembly in this section.
regulator
valve
Transmission INSTALL a new mechatronic assembly. REFER to Mechatronic Assembly in

Control this section.
Module
(TCM)
mechatronic
unit
failed
Engagement Concerns: Delayed/Soft Forward

206 ROUTINE
Transmission Fluid
and seal
assembly

plugged,
damaged
Mechatronics
Solenoid A CONNECT the scan tool and clear the DTCs. ROAD TEST the vehicle and

(SSA) check for DTCs. If the DTC returns, install a new mechatronic unit. REFER

latch valve
Transmission INSTALL a new mechatronic assembly. REFER to Mechatronic Assembly in

Control this section.
Module
(TCM)
mechatronic
unit
failed
Engagement Concerns: No Forward and No Reverse

207 ROUTINE
Transmission Fluid
Incorrect level CHECK the transmission fluid level. ADJUST transmission fluid to correct
level. REFER to Transmission Fluid Level Check in this section.
Selector Lever
Linkage
(Internal/External)
Damaged, out INSPECT for damage, repair as required.

of
aadjustment
Transmission Filter
and Seal Assembly
Not seated, INSPECT for position, damage and restriction. INSTALL a new filter and
damaged or seal assembly. .
plugged
INSPECT for crack or damage. INSTALL new as required.
Pump adapter
Seal
Mechatronics
Manual Valve INSPECT for damage. Replace as required.
Mounting bolt INSPECT for loose mechatronic assembly to transmission bolts. Tighten to
torque specification.

Solenoid INSPECT for valve stuck in spring compressed position or broken spring.
Pressure CLEAN or REPLACE mechatronic assembly as required. REFER to
Regulator Mechatronic Assembly .
Valve
Pump Assembly
Gear INSPECT for damage. REPLACE as required.
Sun gear INSPECT for damage. REPLACE as required.

hub/splines
Other Possible
Components
Turbine shaft INSPECT for damage. REPAIR as required.
Front INSPECT for damage. REPAIR as required.

planetary gear
set INSPECT for damage. REPAIR as required.
Forward INSPECT for damage. REPAIR as required.

clutch drum
Output
shaft/ring gear
Engagement Concerns: Harsh Forward and Harsh Reverse

208 ROUTINE
Transmission Fluid

Transmission fluid filter INSTALL a new transmission fluid filter assembly. REFER to
and seal assembly Fluid Pan, Gasket and Filter in this section.
plugged, damaged
Powertrain Control System
PCM electrical PERFORM On-Board Diagnostic (OBD) tests. REPAIR as

inputs/outputs, required. CLEAR the DTCs. ROAD TEST and PERFORM
Transmission Control the OBD test again.
Module (TCM), external
vehicle wiring harnesses,
solenoids, Transmission
Range (TR) sensor, Shift
Solenoid A (SSA), Pressure
Control Solenoid A (PCA)

Multiple shift missing If some shifts are missing, determine which shifts do not
(more than one gear) occur. REFER to clutch and solenoid application charts in this
section. MONITOR appropriate PIDs as listed in diagnostics.
REFER to Routine 210.
Mechatronics
Electronic component REMOVE the mechatronic unit. INSPECT and CLEAN the
failure shift solenoid terminals on the mechatronic leadframe for
metallic contamination. INSTALL the mechatronic unit.
REFER to Mechatronic Assembly in this section. CONNECT
the scan tool and clear the DTCs. ROAD TEST the vehicle
and check for DTCs. If the DTC returns, install a new
mechatronic unit. REFER to Mechatronic Assembly in this
section. After installing the new mechatronic unit, it must be
programmed with the latest calibration.
Engagement Concerns: Delayed Forward and Delayed Reverse

209 ROUTINE
Transmission Fluid

Transmission fluid filter INSTALL a new transmission fluid filter assembly. REFER to
and seal assembly Fluid Pan, Gasket and Filter in this section.
plugged, damaged
Mechatronics
Mechatronic unit INSTALL a new mechatronic assembly. REFER to

failed Mechatronic Assembly in this section.
Shift Concerns: Some/All Shifts Missing

210 ROUTINE
Transmission Fluid
Incorrect level CHECK the transmission fluid level.

ADJUST transmission fluid to correct level.
REFER to Transmission Fluid Level Check
in this section.

Transmission fluid filter and seal assembly INSTALL a new transmission fluid filter
plugged, damaged assembly. REFER to Fluid Pan, Gasket and
Filter in this section.
Selector Lever Linkage Damaged or Incorrectly
Adjusted
Selector lever cable INSPECT and REPAIR as required.

VERIFY selector lever cable adjustment.
REFER to Section 307-05 . ADJUST
selector lever cable as necessary.
Forward Clutch (A) Assembly (No Shifts)
Seals, piston damaged INSPECT and REPAIR as required.
Friction elements damaged or worn INSPECT and REPAIR as required.
Return springs damaged INSPECT and REPAIR as required.

PCM electrical inputs/outputs, Transmission PERFORM On-Board Diagnostic (OBD)

Control Module (TCM), vehicle wiring tests. REPAIR as required. CLEAR the
harnesses, solenoids, Transmission Range DTCs. ROAD TEST and PERFORM the
(TR) sensor, Shift Solenoid A (SSA), OBD test again.
Pressure Control Solenoid A (PCA)
Multiple shift missing (more than one gear) If some shifts are missing, determine which
shifts do not occur. REFER to the Clutch and
Solenoid Application Charts in this section.
MONITOR appropriate PIDs as listed in
diagnostics.
Shift Concerns: Timing Early/Late

211 ROUTINE
PCM electrical inputs/outputs, PERFORM On-Board Diagnostic (OBD) tests. REPAIR

Transmission Control Module as required. CLEAR the DTCs. ROAD TEST and
(TCM), vehicle wiring harnesses PERFORM the OBD test again.
Engine driveability concerns REFER to Section 303-00 .

Mechatronics
Bolts not tightened to TIGHTEN to specification.

specification

Mechatronic unit contaminated, INSPECT for damage. If damaged, INSTALL a new

solenoid(s) damaged, stuck or mechatronic assembly. REFER to Mechatronic
bore damaged. Manual valve Assembly in this section.
damaged, stuck or bore damaged
Incorrect Pressures
Application pressures are Incorrect application pressures may be due to

incorrect non-transmission components, mechatronic assembly or
internal transmission damage. REPAIR all
non-transmission components then continue with this
routine.
Other
Tire size change, axle ratio VERIFY the vehicle has the original equipment.
change REFER to the Vehicle Certification (VC) label.
Changes in tire size and axle ratio will affect shift
timing.
Shift Concerns: Timing Erratic/Hunting

212 ROUTINE
Transmission Fluid
Incorrect level CHECK the transmission fluid level.

ADJUST transmission fluid to correct
level. REFER to Transmission Fluid
Level Check in this section.
Condition CARRY OUT Transmission Fluid

Condition Check. REFER to Preliminary
Inspection in this section.
Transmission fluid over temperature REFER to Transmission Overheating,

condition Routine 257.
PCM electrical inputs/outputs, PERFORM On-Board Diagnostic (OBD)

Transmission Control Module (TCM), tests. REPAIR as required. CLEAR the
vehicle wiring harnesses DTCs. ROAD TEST and PERFORM the
OBD test again.
Torque Converter Concerns
Torque Converter Clutch (TCC) REFER to Torque Converter Operation

Concerns: Cycling/Chatter.

Feel Concerns: Soft/Slipping (some or all)

213 ROUTINE
Transmission Fluid
Incorrect level CHECK the transmission fluid level. ADJUST transmission fluid to
correct level. REFER to Transmission Fluid Level Check in this
section.
Transmission fluid INSTALL a new transmission fluid filter assembly. REFER to Fluid
filter and seal Pan, Gasket and Filter in this section.
assembly
plugged, damaged
PCM electrical PERFORM On-Board Diagnostic (OBD) tests. REPAIR as required.

inputs/outputs, CLEAR the DTCs. ROAD TEST and PERFORM the OBD test again.
Transmission
Control Module
(TCM), vehicle
wiring harnesses
Transmission Fluid
Temperature (TFT) Sensor
Damaged
Mechatronic REMOVE the mechatronic unit. INSPECT and CLEAN the TFT
assembly terminals on the mechatronic leadframe for metallic contamination.
INSTALL the mechatronic unit. REFER to Mechatronic Assembly in
this section. CONNECT the scan tool and clear the DTCs. ROAD
TEST the vehicle and check for DTCs. If the DTC returns, install a
new mechatronic unit. REFER to Mechatronic Assembly in this
Bolts not tightened TIGHTEN to specification.

to specification
Mechatronic unit INSPECT for damage. If damaged, install a new mechatronic

contaminated, assembly. REFER to Mechatronic Assembly in this section.
solenoid(s)
damaged, stuck or
bore damaged.
Manual valve
damaged, stick or
bore damaged
Feel Concerns: Harsh (some or all)


214 ROUTINE
Transmission Fluid
section.
Transmission fluid INSTALL a new transmission fluid filter assembly. REFER to Fluid
filter and seal Pan, Gasket and Filter in this section.
assembly
plugged, damaged
PCM electrical PERFORM On-Board Diagnostic (OBD) tests. REPAIR as

inputs/outputs, required. CLEAR the DTCs. REPROGRAM the mechatronic
Transmission Control assembly with the latest calibration. CARRY OUT Shift Point Road
Module (TCM), Test Adaptive Drive Cycle, REFER to Shift Point Road Test in
vehicle wiring this section. ROAD TEST and PERFORM the OBD test.
harnesses
Mechatronics
Bolts not tightened to TIGHTEN bolts to specification.

specification
Mechatronic assembly INSPECT for damage. If damaged install a new mechatronic

contaminated, assembly. REFER to Mechatronic Assembly in this section.
solenoid(s) damaged,
solenoids stuck or
bore damaged
Manual valve INSPECT for damage. If damaged install a new mechatronic

damaged, stuck or assembly. REFER to Mechatronic Assembly in this section.
bore damaged
Feel Concerns: No 1st Gear, Engages in Higher Gear

215 ROUTINE
PCM electrical inputs/outputs, PERFORM On-Board Diagnostic (OBD) tests.

Transmission Control Module REPAIR as required. CLEAR the DTCs. ROAD
(TCM), vehicle wiring harnesses TEST and PERFORM the OBD test.
Incorrect Gear
Mechatronic failure

DETERMINE which gear the transmission is in.

REFER to the Clutch and Solenoid Application
Charts in this section.
Feel Concerns: No Manual 1st Gear

216 ROUTINE
Transmission Fluid
correct level. REFER to Transmission Fluid Level Check in this section.
fluid filter and Gasket and Filter in this section.
seal assembly
plugged,
damaged
Selector Lever Linkage
Selector lever INSPECT and REPAIR as necessary.

cable system
damaged,
misaligned
Mechatronics
failure contamination. INSTALL the mechatronic unit. REFER to Mechatronic
Assembly in this section. CONNECT the scan tool and clear the DTCs.
ROAD TEST the vehicle and check for DTCs. If the DTC returns, install
a new mechatronic unit. REFER to Mechatronic Assembly in this
Defective Shift INSPECT and CLEAN the SSA terminals on the mechatronic leadframe
Solenoid A for metallic contamination. REFER to Mechatronic Assembly in this
(SSA) section. CONNECT the scan tool and clear the DTCs. ROAD TEST the
vehicle and check for DTCs. If the DTC returns, install a new
mechatronic unit. REFER to Mechatronic Assembly in this section. After
installing the new mechatronic unit, it must be programmed with the
latest calibration.
Powertrain Control
System

inputs/outputs, CLEAR the DTCs. ROAD TEST and PERFORM the OBD test.
Transmission

Control Module
(TCM), vehicle
wiring harnesses
Clutch Plates
Forward clutch INSPECT the forward clutch assembly for damage. REPAIR as required.
(A) friction and REFER to Forward Clutch Assembly in this section.
steel plate
failure
Low/reverse INSPECT the low/reverse clutch assembly for damage. REPAIR as

clutch (D) required. REFER to Low/Reverse Clutch Assembly in this section.
friction and steel
plate failure
Pump
Pump gear INSTALL a new pump assembly. REFER to Pump Assembly in this
failure section.
Feel Concerns: No Manual 2nd Gear

217 ROUTINE
Transmission Fluid
correct level. REFER to Transmission Fluid Level Check in this section.
fluid filter and Gasket and Filter in this section.
seal assembly
plugged,
damaged

cable system
damaged,
misaligned
Mechatronics

Defective Shift INSPECT and CLEAN the SSA terminals on the mechatronic leadframe
Solenoid A for metallic contamination. REFER to Mechatronic Assembly in this
(SSA) section. CONNECT the scan tool and clear the DTCs. ROAD TEST the
latest calibration.
Powertrain Control
System

Transmission
Control Module
(TCM), vehicle
wiring harnesses
Clutch Plates
steel plate
failure

friction and steel
plate failure
Pump
failure section.
Feel Concerns: No Manual 3rd Gear

218 ROUTINE

cable system
damaged,
misaligned
Mechatronics


Defective Shift INSPECT and CLEAN the SSB terminals on the mechatronic leadframe
Solenoid B for metallic contamination. REFER to Mechatronic Assembly in this
(SSB) section. CONNECT the scan tool and clear the DTCs. ROAD TEST the
latest calibration.
Powertrain Control
System

Transmission
Control Module
(TCM), vehicle
wiring harnesses
Clutch Plates
steel plate
failure
Direct clutch (B) INSPECT the direct clutch assembly for damage. REPAIR as required.
friction and steel REFER to Direct Clutch Assembly in this section.
plate failure

friction and steel
plate failure.
Pump
failure section.
Feel Concerns: No 1-2 Shift

220 ROUTINE
Transmission Fluid

and seal
assembly

plugged,
damaged
Mechatronics
Defective INSPECT and CLEAN the SSC terminals on the mechatronic leadframe for
Solenoid C CONNECT the scan tool and clear the DTCs. ROAD TEST the vehicle and
(SSC) check for DTCs. If the DTC returns, install a new mechatronic unit. REFER
Defective INSPECT and CLEAN the SSD terminals on the mechatronic leadframe for
Solenoid D CONNECT the scan tool and clear the DTCs. ROAD TEST the vehicle and
(SSD) check for DTCs. If the DTC returns, install a new mechatronic unit. REFER

regulator
valve

latch valve

clutch C to Mechatronic Assembly in this section.
regulator
valve
Mechatronic INSTALL a new mechatronic assembly. REFER to Mechatronic Assembly in

unit this section.
failed
Clutch Plates

Intermediate INSPECT the intermediate clutch assembly for damage. REPAIR as required.
clutch (C) REFER to Intermediate Clutch Assembly in this section.
friction and
steel plate
failure
friction and
steel plate
failure

221 ROUTINE
Transmission Fluid
and seal
assembly

plugged,
damaged
Mechatronics
(SSB) check for DTCs. If the DTC returns, install a new mechatronic unit. REFER
Solenoid C CONNECT the scan tool and clear the DTCs. ROAD TEST the vehicle and
(SSC) check for DTCs. If the DTC returns, install a new mechatronic unit. REFER



regulator
valve

latch valve

clutch C to Mechatronic Assembly in this section.
regulator
valve

unit this section.
failed
Clutch Plates
Direct INSPECT the direct clutch assembly for damage. REPAIR as required.
clutch (B) REFER to Direct Clutch Assembly in this section.
friction and
steel plate
failure
friction and
steel plate
failure
Possible
222 ROUTINE
Mechatronics
failure CONNECT the scan tool and clear the DTCs. ROAD TEST the vehicle and

Solenoid CONNECT the scan tool and clear the DTCs. ROAD TEST the vehicle and
B (SSB) check for DTCs. If the DTC returns, install a new mechatronic unit. REFER to
D (SSD) check for DTCs. If the DTC returns, install a new mechatronic unit. REFER to
Defective INSPECT and CLEAN the SSE terminals on the mechatronic leadframe for
E (SSE) check for DTCs. If the DTC returns, install a new mechatronic unit. REFER to

clutch B Mechatronic Assembly in this section.
regulator
valve

latch
valve

clutch E Mechatronic Assembly in this section.
regulator
valve

solenoid Mechatronic Assembly in this section.
multiplex
valve

unit this section.
failed
Clutch Plates
friction
and steel
plate
failure

Overdrive Inspect the overdrive clutch assembly for damage. Repair as required. Refer to
clutch (E) Overdrive Clutch Assembly in this section.
friction
and steel
plate
failure
Possible
223 ROUTINE
Mechatronics
D (SSD) check for DTCs. If the DTC returns, install a new mechatronic unit. REFER to

regulator
valve

latch
valve

regulator

valve
Solenoid INSPECT mechatronic assembly for stuck valves or contamination. REFER to

multiplex Mechatronic Assembly in this section.
valve
Drive INSPECT mechatronic assembly for stuck valves or contamination. REFER to

enable Mechatronic Assembly in this section.
valve

unit this section.
failed
Clutch Plates
friction
and steel
plate
failure
Overdrive INSPECT the overdrive clutch assembly for damage. REPAIR as required.
clutch (E) REFER to Overdrive Clutch Assembly in this section.
friction
and steel
plate
failure
Possible
224 ROUTINE
Mechatronics

C (SSC) check for DTCs. If the DTC returns, install a new mechatronic unit. REFER to

regulator
valve

latch valve

clutch C Mechatronic Assembly in this section.
regulator
valve

unit this section.
failed
Clutch Plates
friction
and steel
plate
failure
friction
and steel
plate
failure
Possible
225 ROUTINE
Mechatronics


regulator
valve

clutch D Mechatronic Assembly in this section.
regulator
valve

unit this section.
failed
Clutch Plates
clutch (C) to Direct Clutch Assembly in this section.
friction
and steel
plate
failure
friction
and steel
plate
failure
Torque Converter Operation Concerns: No Apply

240 ROUTINE
Transmission Fluid

Condition CARRY OUT the Transmission Fluid Condition Check.

REFER to Preliminary Inspection in this section.
Mechatronics
Defective Torque INSPECT and CLEAN the TCC solenoid terminals on the
Converter Clutch (TCC) mechatronic leadframe for metallic contamination. REFER to
solenoid Mechatronic Assembly in this section. CONNECT the scan
tool and clear the DTCs. ROAD TEST the vehicle and check
for DTCs. If the DTC returns, install a new mechatronic unit.
installing the new mechatronic unit, it must be programmed
with the latest calibration.
Defective torque converter INSPECT mechatronic assembly for stuck valves or

apply regulator valve contamination. REFER to Mechatronic Assembly in this
section.

release regulator valve contamination. REFER to Mechatronic Assembly in this
section.
Mechatronic assembly TIGHTEN to specification.

bolts not tightened to
specification

contaminated, solenoid(s) assembly. REFER to Mechatronic Assembly in this section.
damaged, stuck or bore
damaged. Manual valve
damaged
PCM
Powertrain control system PERFORM On-Board Diagnostic (OBD) tests. REPAIR as

electrical inputs/outputs, required. CLEAR the DTCs. ROAD TEST and PERFORM the
Transmission Control OBD test.
Module (TCM), vehicle
wiring harnesses, TCC
solenoid, Transmission
Fluid Temperature (TFT)
sensor
Torque Converter
Torque converter REMOVE the transmission. INSPECT for damage. INSTALL

components a new or remanufactured torque converter. REFER to
Transmission Four Wheel Drive (4WD) or Transmission
Rear Wheel Drive (RWD) in this section.
Torque Converter Operation Concerns: Cycling/Chatter


241 ROUTINE
Transmission Fluid

Mechatronics

apply regulator valve contamination. REFER to Mechatronic Assembly in this
section.

specification

damaged
PCM

sensor
Torque Converter
Torque converter REMOVE the transmission. INSPECT for damage. INSTALL

components a new or remanufactured torque converter. REFER to

Torque Converter Operation Concerns: Always Applied/Stalls Vehicle

242 ROUTINE
Transmission Fluid

Mechatronics

specification

damaged
PCM

sensor
Torque Converter
Torque converter REMOVE the transmission. INSPECT for damage. Install a

components new or remanufactured torque converter. REFER to
Other Concerns: External Leaks


252 ROUTINE
Transmission Fluid
section.
Transmission case INSPECT and REPAIR as necessary.

vent damaged,
case porosity
Leakage at gaskets, REFER to Leakage Inspection , Fluid Leakage in Torque Converter

seals, bulkhead Area and Transmission Leak Check Test Procedures in this section for
connector potential leak locations. REMOVE all traces of lubricant on exposed
surface of the transmission. REPAIR as necessary.
Transmission Fluid Cooler
Tubes
Transmission fluid LOCATE leak source. REPAIR as required. REFER to Section 307-02
cooler tube fittings .
Transmission fluid LOCATE leak source. REPAIR as required. REFER to Section 307-02
cooler tube .
O-rings,
transmission fluid
cooler tubes
Torque Converter
Torque converter INSTALL a new torque converter.

studs
Torque converter INSTALL a new torque converter hub seal.

hub seal

weld
Transmission Case
Case leaking INSTALL a new transmission case. REFER to Transmission in this

section.
Transmission INSTALL a new transmission electrical connector O-ring.

electrical connector
Transmission fluid INSTALL a new transmission fluid fill plug.

fill plug
Output shaft seal INSTALL a new seal. REFER to Output Shaft Seal in this section.

Manual control INSTALL a new seal.

valve lever seal
Transmission fluid INSTALL a new seal.

pan seal (gasket)
Fluid Pump
Fluid pump O-ring INSTALL a new O-ring. REFER to Pump Assembly in this section.
Fluid pump seal INSTALL a new seal ring. REFER to Pump Assembly in this section.
ring
Noise/Vibration in Forward or Reverse

254 ROUTINE
Transmission Fluid
Incorrect level (low) pump CHECK the transmission fluid level. ADJUST transmission
cavitation fluid to correct level. REFER to Transmission Fluid Level
Transmission Fluid Cooler Tubes
Transmission fluid cooler ADJUST or reposition cooler tubes.

tubes grounding out
Torque Converter
Check the torque converter LOCATE source of disturbance. REPAIR as required.

components/balance weight
Engine Driveline
Engine drive accessories REFER to Section 303-00 .
Engine Will Not Crank

255 ROUTINE
Selector Lever Cable System

Selector lever cable system INSPECT and REPAIR as necessary. REFER to Section
damaged, misaligned 307-05 .
Electrical inputs/outputs, PERFORM On-Board Diagnostic (OBD) tests. REFER to

Transmission Control Module the Powertrain Control/Emissions Diagnosis (PC/ED)
(TCM), vehicle wiring manual for diagnosis and testing of engine components.
harnesses, engine starting CHECK PIDs for TR park and neutral positions. REPAIR as
system, Transmission Range required. CLEAR the DTCs. ROAD TEST and PERFORM
(TR) sensor the OBD test.
Torque Converter
Flexplate damaged INSPECT and REPAIR as necessary.

Vehicle Starter
Starter system concerns INSPECT and REPAIR as necessary. REFER to Section

303-06 .
TR Sensor Assembly
TR assembly damaged INSPECT and REPAIR as necessary.

Fluid Pump Assembly
Internal parts seized INSPECT and REPAIR as necessary.
No Park (P) Range

256 ROUTINE
Selector Lever Cable
Selector lever cable system damaged, misaligned INSPECT and REPAIR as

necessary.
Manual control lever assembly damaged, manual valve inner INSPECT and REPAIR as
lever pin bent, manual valve inner lever damaged, spring rod necessary.
damaged, park pawl pin loose or damaged, park rod actuating
plate loose, damaged or missing
Transmission case assembly INSPECT and REPAIR as

necessary.
Park gear, park pawl, park pawl return spring, part or guide, INSPECT and REPAIR as
park actuating rod, park pawl shaft, manual lever necessary.
External linkages/brackets damaged INSPECT and REPAIR as

necessary.
Transmission Range (TR) Assembly Damaged

Manual lever detent spring
TR assembly INSTALL a new

mechatronic assembly.
Assembly in this section.
Transmission Overheating

257 ROUTINE
Transmission Fluid
Incorrect level CHECK transmission fluid level. ADJUST transmission fluid

to correct level. REFER to Transmission Fluid Level Check in
this section.

Electrical inputs/outputs, PERFORM On-Board Diagnostic (OBD) tests. REFER to the

Transmission Control Powertrain Control/Emissions Diagnosis (PC/ED) manual for
Module (TCM), vehicle diagnosis and testing of engine components. CHECK PIDs for
wiring harnesses, Torque Transmission Range (TR) park and neutral positions. REPAIR
Converter Clutch (TCC) as required. CLEAR the DTCs. ROAD TEST and PERFORM
solenoid the OBD test.
Torque Converter Not Engaging

Case Vent Damaged
Transmission case INSPECT and REPAIR as necessary.

assembly
Other
Restriction in transmission CHECK transmission cooling system efficiency. REFER to

cooling system Section 307-02 for automatic transmission cooling system
diagnostic procedures.
Excessive trailer tow load REFER to the Owner's Literature for specifications on trailer
towing.
Vehicle heat shield INSPECT and REPAIR as necessary.

missing or damaged
INSPECT and REPAIR as necessary.

Vehicle airflow is
restricted
Thermal bypass valve INSPECT for damage. If damaged, repair as necessary. REFER
missing or damaged to Mechatronic Assembly .
Fluid Venting/Foaming

261 ROUTINE
Transmission Fluid
Case Vent Damaged
Transmission INSPECT and REPAIR as necessary.

case
assembly
Shift Concerns: No 4-5 Shift
Possible
270 ROUTINE
Mechatronics
Electronic Remove the mechatronic unit. Inspect and clean the shift solenoid terminals on
component the mechatronic leadframe for metallic contamination. Install the mechatronic
unit. Refer to Mechatronic Assembly in this section. Connect the scan tool and
failure clear the DTCs. Road test the vehicle and check for DTCs. If the DTC returns,
install a new mechatronic unit. Refer to Mechatronic Assembly in this section.
After installing the new mechatronic unit, it must be programmed with the latest
calibration.
Defective Inspect and clean the SSA terminals on the mechatronic leadframe for metallic
Shift contamination. Refer to Mechatronic Assembly in this section. Connect the scan
Solenoid tool and clear the DTCs. Road test the vehicle and check for DTCs. If the DTC
A (SSA) returns, install a new mechatronic unit. Refer to Mechatronic Assembly in this
section. After installing the new mechatronic unit, it must be programmed with
Defective Inspect and clean the SSB terminals on the mechatronic leadframe for metallic
Shift contamination. Refer to Mechatronic Assembly in this section. Connect the scan
Solenoid tool and clear the DTCs. Road test the vehicle and check for DTCs. If the DTC

B (SSB) returns, install a new mechatronic unit. Refer to Mechatronic Assembly in this
section. After installing the new mechatronic unit, it must be programmed with
Defective Inspect mechatronic assembly for stuck valves or contamination. Refer to

regulator
valve

latch
valve

regulator
valve
Mechatronic Install a new mechatronic assembly. Refer to Mechatronic Assembly in this

unit section.
failed
Clutch Plates
Forward Inspect the forward clutch assembly for damage. Repair as required. Refer to
clutch (A) Forward Clutch Assembly in this section.
friction
and steel
plate
failure
Direct Inspect the direct clutch assembly for damage. Repair as required. Refer to
clutch (B) Direct Clutch Assembly in this section.
friction
and steel
plate
failure
Possible
271 ROUTINE
Mechatronics


regulator
valve

latch
valve

regulator
valve

unit this section.
failed
Clutch Plates
friction
and steel
plate
failure
Forward INSPECT the forward clutch assembly for damage. REPAIR as required.
clutch (A) REFER to Forward Clutch Assembly in this section.
friction
and steel
plate
failure
Possible

272 ROUTINE
Mechatronics

regulator
valve

latch valve

regulator
valve

unit this section.
failed
Clutch Plates
friction
and steel
plate
failure

friction
and steel
plate
failure
Possible
273 ROUTINE
Mechatronics

regulator
valve

latch valve

regulator
valve

unit this section.
failed
Clutch Plates

friction
and steel
plate
failure
friction
and steel
plate
failure


6R80 Manual
Transmission Fluid Cooler Backflushing and Cleaning
Special Tool(s)
Transmission Heated Cooler Line Flusher

222-00007, 222-00004 or equivalent
NOTICE: Do not use any supplemental transmission fluid additives or cleaning agents. The use of these
products could cause internal transmission components to fail; this will affect the operation of the
transmission.
NOTE: Transmission fluid cooler backflushing and cleaning will be performed using the Transmission
Heated Cooler Line Flusher or equivalent. Follow the manufacturer's instructions included with the machine.
Test the equipment to make sure that a vigorous fluid flow is present before proceeding.
NOTE: If the Transmission Heated Cooler Line Flusher or equivalent is not available, install a new
transmission fluid cooler and/or an auxiliary transmission fluid cooler.
1. Check and top off the fluid level of the cooler line flusher with transmission fluid.
2. Allow the transmission fluid in the cooler line flusher 15-30 minutes to heat up to 60C (140F)
before using.
3. Install the line adapters into the transmission fluid cooler tubes.
4. Attach the cooler line flusher red line to the transmission fluid cooler pressure tube quick connect
fitting.
5. Attach the cooler line flusher blue line to the transmission fluid cooler return tube quick connect
fitting.
6. Follow the equipment instructions to purge the transmission fluid cooler tubes and cooler prior to
starting the flushing procedure.
7. Allow the transmission fluid cooling system to backflush for 10-15 minutes, then flush the
transmission fluid cooler in a normal flow direction for an additional 10-15 minutes.
Transmission Fluid Cooler Backflushing and Cleaning 2592

body>
Transmission Fluid Cooler Backflushing and Cleaning 2593


6R80 Manual
Transmission Fluid Drain and Refill
Special Tool(s)
Rubber Tip Air Nozzle

100-D009 (D93L-7000-A)
Transmission Fluid Fill Tube

307-570
Transporter Fluid Evacuator/Injector

Vacuum Pump Kit


Material
Item Specification
XT-10-QLVC
Drain
1. With the vehicle in NEUTRAL, position it on a hoist. For ational information, refer to Section 100-02
.
2. Remove the transmission fluid pan and allow the transmission fluid to drain.
3. NOTE: The transmission fluid pan gasket can be reused if not damaged.
Install a new transmission fluid pan gasket, if required.
Transmission Fluid Drain and Refill 2594

4. Install the transmission fluid pan and tighten the bolts in a crisscross pattern.
Refill
NOTICE: This procedure contains the air purge steps required to purge air from the transmission fluid
cooling system. This procedure is NOT intended for use with the Transmission Fluid Level Check.
result.
NOTICE: The use of any other transmission fluid than specified can result in the transmission failing to
operate in a normal manner or transmission failure.
NOTE: Here is an overview of the Transmission Fluid Drain and Refill procedure.
Adding 3.3L (3.5 qt) of transmission fluid to the transmission is an initial fill enabling the engine to
be started.
The cold level range shown in the procedure allows the vehicle to be driven.
The vehicle should be driven to allow the Transmission Fluid Temperature (TFT) to reach 85C-88C
(185F-190F) in order to purge the air from the transmission fluid cooling system.
Fill the transmission fluid to the fill range on the transmission fluid level indicator at the normal
operating range 80C-85C (176F-185F).
1. NOTE: The transmission will need 3.3L (3.5 qt) of transmission fluid added to the transmission as an
initial fill if:
a new mechatronic assembly has been installed.

the transmission fluid pan or transmission fluid filter have been removed.
NOTE: The transmission will need 11.35L (12 qt) of transmission fluid added to the transmission as
an initial fill if the transmission has been overhauled.

Using the Transmission Fluid Fill Tube, add the transmission fluid tansmission through the
transmission fluid fill hole. For additional information, refer to Adding Additional Transmission Fluid
in this procedure.
2. Separate the transmission fluid level indicator from the transmission fluid fill plug.
3. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator only
back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a
consistent reading is established.
4. NOTE: The transmission can have 2 types of transmission fluid level indicators, the original or the
replacement. The original transmission fluid level indicator has a single crosshatch area for the fluid
level. The replacement has 2 areas for the fluid level, a crosshatched (labeled A) area and a dotted
(labeled B) area.
Add transmission fluid to the cold level location as shown in the illustration.
1. Original transmission fluid level indicator

2. Replacement transmission fluid level indicator
5. Install the transmission fluid fill plug.


6. While driving the vehicle, use the scan tool to verify that the TFT has reached a temperature of 88C
(190F). This will circulate the transmission fluid through the torque converter and the transmission
fluid cooling system, eliminating any trapped air in the transmission fluid cooling system.
With the engine idling (600-750 rpm) in PARK, verify that the TFT is between 80C-85C
(176F-185F).
7. Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the
passenger side front portion of the transmission case.
8. Separate the transmission fluid level indicator from the traion fluid fill plug.
back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a
consistent reading is established.
(labeled B) area. Use the crosshatched area when checking the transmission fluid level. The correct
transmission fluid level is at the upper level of the crosshatch marks on the transmission fluid level
indicator.
Using the scan tool verify that the TFT is between 80C-85C (176F-185F). The transmission fluid
level must be at the upper level of the crosshatch mark.


11. NOTE: If the transmission fluid is not at the correct level, follow the steps for Adding
Additional Transmission Fluid or Removing Transmission Fluid in this procedure.
Install the transmission fluid fill plug.
Adding Additional Transmission Fluid
NOTE: To get an accurate transmission fluid level reading the engine should be idling (600-750 rpm)
in PARK.
1. Install the Transmission Fluid Fill Tube into the transmission fluid fill hole.
2. Fill the Transporter Fluid Evacuator/Injector with approximately 0.47L (1 pt) of transmission
fluid.
3. Hang the Transporter Fluid Evacuator/Injector under the vehicle, upright and close to the
transmission.

4. Connect the Transporter Fluid Evacuator/Injector and Transmission Fluid Fill Tube.
Connect the open end of the fluid hose from the Transporter Fluid Evacuator/Injector
onto the Transmission Fluid Fill Tube from the transmission case.
5. Use a Rubber Tip Air Nozzle to apply a maximum of 206.85 kPa (30 psi) to the open end of
the vacuum/pressure hose from the Transporter Fluid Evacuator/Injector. Transmission fluid
will immediately start flowing out of the Transporter Fluid Evacuator/Injector into the
transmission.
6. NOTE: Do not overfill the transmission. The transmission fluid level must be at the upper
level of the crosshatch mark.
Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug
hole to check the transmission fluid level. Repeat this until a consistent reading is established.
7. Using the scan tool, verify that the TFT is between 80C-85C (176F-185F). The
transmission fluid level must be at the upper level of the crosshatch mark.

8. NOTE: If the transmission fluid is over full, follow the steps for Removing Transmission
Fluid in this procedure.
Removing Transmission Fluid
NOTE: To get an accurate transmission fluid level reading the engine should be idling (600-750 rpm)
in PARK.
1. If the transmission is overfilled, transmission fluid must be removed to the correct level. Use
the Transporter Fluid Evacuator/Injector and the Vacuum Pump Kit to extract any excessive
transmission fluid.
2. Using the scan tool, verify that the TFT is between 80C-85C (176F-185F). The
transmission fluid level must be at the upper level of the crosshatch mark. Reinstall the
transmission fluid level indicator only back into the transmission fluid fill plug hole to check
the transmission fluid level. Repeat this until a consistent reading is established.

3. Install the transmission fluid fill plug.



6R80 Manual
Transmission Fluid Exchange
Special Tool(s)
Heavy-Duty Transmission and Power

Steering Fluid X-Changer
Material
Item Specification
XT-10-QLVC
NOTICE: Use transmission fluid specific for this transmission. Do not use any supplemental
transmission fluid additives or cleaning agents. The use of these products can cause internal
transmission components to fail, which will affect the operation of the transmission.
NOTE: For best results, perform the transmission cooler backflush and cleaning procedure before exchanging
the fluid.
1. With the vehicle in NEUTRAL, position it on a hoist. Refer to Section 100-02 .
2. Connect the Heavy-Duty Transmission and Power Steering Fluid X-Changer to the transmission fluid
cooler tube after the transmission fluid cooler on the return tube. This will help remove any foreign
material trapped in the transmission fluid coolers.
3. Perform the transmission fluid exchange using the Heavy-Duty Transmission and Power Steering
Fluid X-Changer. Follow the manufacturer's instructions included with the machine.
4. Once the transmission fluid exchange is completed, disconnect the Heavy-Duty Transmission and
Power Steering Fluid X-Changer. Recect any disconnected transmission fluid cooler tubes.
5. Using the scan tool with the engine running, check and make sure that the transmission is at normal
operating temperature 66-77C (150-170F). Check and adjust the transmission fluid level and check
for any leaks. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt)
until the correct level is achieved.
Transmission Fluid Exchange 2602

Transmission Fluid Exchange 2603


6R80 Manual
Transmission Fluid Level Check
Special Tool(s)

Material
Item Specification
result.
NOTE: If the vehicle has been operated for an extended period at high highway speeds, in city traffic, during
hot weather or while pulling a trailer, the transmission fluid must cool down to obtain an accurate reading.
NOTE: Do not overfill the transmission. The transmission fluid level must be at the upper level of the
crosshatch mark.
NOTE: If the installation of a new transmission fluid cooler or transmission fluid cooler tubes has been
carried out, the vehicle must be driven to get the transmission fluid to a temperature of 88C (190F) in order
to purge the air from the transmission fluid cooling system.
1. With the engine running, place the transmission selector lever in each gear position and hold
approximately 5 seconds. Place the transmission selector lever in PARK.
2. With the engine idling (600-750 rpm) in PARK, position it on a hoist. For additional information,
3. Remove the transmission fluid fill plug transmission fluid level indicassembly, located on the
passenger side front portion of the transmission case.
Transmission Fluid Level Check 2604

4. Separate the transmission fluid level indicator from the transmission fluid fill plug.
back into the transmission fluid fill plug hole to check the transmission fluid level.
(labeled B) area. Use the crosshatched area when checking the transmission fluid level. The correct
transmission fluid level is at the upper level of the crosshatch marks on the transmission fluid level
indicator.
Using the scan tool, verify that the Transmission Fluid Temperature (TFT) is between 80C-85C
(176F-185F). Do not overfill the transmission. The transmission fluid level must be at the upper
level of the crosshatch mark.

7. NOTE: If the transmission fluid is not at the correct level, follow the steps for Adding Additional
Transmission Fluid or Removing Transmission Fluid. For additional information, refer to
Transmission Fluid Drain and Refill in this section.



6R80 Manual
Torque Converter Contamination Inspection
Material
Item Specification
Motorcraft MERCON LV
Automatic Transmission Fluid
XT-10-QLVC td
align="center">MERCON LV
1. A new or remanufactured torque converter must be installed if one or more of the following
statements is true:
A torque converter malfunction has been determined based on complete diagnostic
procedures.
The torque converter stud or studs, impeller hub or bushing are damaged.
The torque converter exhibits external discoloration (due to overheating).
There is evidence of transmission assembly or fluid contamination due to the following
transmission or converter failure modes.
Major metallic failure
Multiple clutch plates or band failures
Sufficient component wear which results in metallic contamination
Water or antifreeze contamination
2. If none of the above conditions are present, continue with the following fluid inspection.
3. Pour a small amount of transmission fluid from the torque converter onto an absorbent white tissue or
through a paper filter.
4. Examine the fluid for contaminants, color and smell. The fluid must be free of contaminants, red in
color and not have a burnt smell.
5. NOTICE: Do not use water-based cleaners or mineral spirits to clean or flush the torque
converter or transmission damage will occur.
If the fluid passed inspection:
drain the remaining fluid from the torque converter.

using only the recommended transmission fluid, add 1.9L (2 qt) of clean fluid into the
converter and agitate by hand.
thoroughly drain the fluid.
Torque Converter Contamination Inspection 2607

P>
Torque Converter Contamination Inspection 2608


6R80 Manual
Fluid Pan, Gasket and Filter
Material
Item Specification
XT-10-QLVC
Removal
NOTICE: The use of any transmission fluid other than specified can result in the transmission failing to
operate in a normal manner or transmission failure.
1. With the vehicle in NEUTRAL, position it on . For additional information, refer to Section 100-02 .
3. Remove the transmission fluid pan gasket.
4. NOTE: The transmission fluid filter may be reused if no excessive contamination is indicated.
Remove and discard the transmission fluid filter.
5. Clean and inspect the transmission fluid pan and magnet.
Fluid Pan, Gasket and Filter 2609

Installation
NOTE: If the transmission is being repaired for a contamination-related failure, install a new transmission
fluid filter and seal assembly. The transmission fluid filter may be reused if no excessive contamination is
indicated.
1. Inspect the transmission case for the transmission fluid filter seal. If the seal is in the case, carefully
remove the seal without scratching the case.
2. Make sure that the seal is on the transmission fluid filter and lubricate the seal with automatic
transmission fluid.
If required, install a new transmission fluid filter.
4. Position the magnet in the transmission fluid pan.

Install a new transmission fluid pan gasket if required.
6. Install the transmission fluid pan and tighten the bolts in a crisscross pattern.
7. Using the Adding Additional Transmission Fluid procedure, fill and check the transmission fluid. For
additional information, refer to Transmission Fluid Drain and Refill in this section.


6R80 Manual
Special Tool(s)

Removal
Mechatronic assembly
NOTICE: The only serviceable solenoid in the mechatronic assembly is Shift Solenoid E (SSE). If the
mechatronic assembly is being removed due to a faulty SSE , follow the specific steps in this procedure
to install a new SSE . If the mechatronic assembly is being removed due to a faulty solenoid other than
SSE , a new mechatronic assembly must be installed.
100-02 .
2. Retrieve the module configuration from the PCM. Carry out the module configuration retrieval steps
of the Programmable Module Installation (PMI) procedure. For additional information, refer to
Section 418-01 .
3. NOTICE: Do not pull on the wire harness to disconnect the connector or damage to the
connector will occur.
Disconnect the transmission vehicle harness connector by twisting the outer shell and pulling back on
the connector.
passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will
relieve any vacuum that might have built up in the transmission. This will aid in allowing the
transmission fluid pan to be easily removed when the bolts are removed.

Remove and discard the transmission fluid filter.
8. Pull the release tab and pull down on the transmission bulkhead electrical connector retainer.
9. NOTICE: Do not touch the electrical connector pins or the exposed solenoid tabs on the
transmission bulkhead electrical connector. Electrostatic discharge may occur and may cause
damage to the mechatronic unit.
With the release tab down, pull the outer shell of the transmission bulkhead electrical connector out of
the mechatronic assembly.

Pull the transmission bulkhead electrical connector out of the transmission case.
11. NOTICE: During removal of the mechatronic assembly, the thermal bypass valve will fall out of
the transmission case. Damage to the valve will occur if the valve falls out.
Remove the 11 bolts from the mechatronic assembly and remove the mechatronic assembly and the
bypass valve.
SSE
12. Remove the 6 long bolts from the TCM unit.
13. Carefully separate the TCM from the mechatronic assembly.

1. TCM
2. Mechatronic assembly
14. Remove the 8 solenoid bracket bolts and the solenoid bracket.
15. Remove SSE .
Installation
SSE
1. Install SSE .
2. Position the solenoid bracket in place and install the 8 bolts.


3. NOTE: The Transmission Range (TR) sensor pin must be aligned with the manual control valve
during installation.
Position the TCM on the mechatronic assembly.
1. TCM
3. TR sensor pin
4. Install the 6 long bolts into the TCM unit. Tighten the bolts in the sequence shown.
Mechatronic assembly
5. NOTE: Before installing the mechatronic assembly into the transmission case, verify the presence
and correct orientation of the thermal bypass valve, pump adapter seal and center support seals. Also
note that one or more of the center support seals may have remained in the mechatronic assembly
during removal and should be installed into the transmission case at this time.
Verify the 4 rubber feed tubes for the center support are in place.
1. Black feed tubes

2. Green feed tube
3. Blue feed tube

6. Verify the rubber adapter is in place.
7. Coat the thermal bypass valve with petroleum jelly to hold it in place and install the thermal bypass
valve in the transmission case.
transmission vehicle harness connector. Electrostatic discharge may occur and may cause
Position the mechatronic assembly in place and loosely install the 11 bolts.
1. Align the manual valve and control lever linkage.
9. Tighten the mechatronic bolts in the sequence shown.

With the release tab down and unlocked, push the outer shell of the transmission bulkhead electrical
connector into the transmission. Make sure that the transmission bulkhead electrical connector is fully
seated into the mechatronic assembly.

11. Press up on the tab and lock the outer shell of the transmission bulkhead electrical connector in place.
Make sure that the locking tab is securely locked.
If required, install a new transmission fluid filter.
Install a new transmission fluid pan gasket, if required.
14. Install the transmission fluid pan and tighten the transmission fluid pan bolts in a crisscross pattern.
15. Connect the transmission vehicle harness connector by pushing it in and twisting the outer shell to
lock it in place.

16. Make sure the transmission fluid is at the correct level, follow the steps for Adding Additional
17. Restore the module configuration. Carry out the module configuration restore steps of the PMI
procedure for the PCM. For additional information, refer to Section 418-01 .


6R80 Manual
Output Shaft Seal
Special Tool(s)
Installer, Rear Seal 4X4

307-637
Rear Seal Installer 4X2

307-638
Remover, Input Shaft Oil Seal

308-375
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
XT-10-QLVC
Item Description
1 7045 Output shaft flange nut
3 7089 Output shaft flange
Output Shaft Seal 2620

4 7052 Output shaft seal

Removal
All vehicles
100-02 .
2. Remove the rear driveshaft. For additional information, refer to Section 205-01 .
3. NOTE: The output shaft flange nut has been staked to prevent it from coming loose. Prior to
removing the nut, remove the stake to prevent damage to the output shaft.
Remove and discard the output shaft flange nut.
4. Remove the extension housing flange seal and the output shaft flange.
5. Using the Input Shaft Oil Seal Remover and Slide Hammer, remove the output shaft seal.
6. Remove the transfer case. For additional information, refer to Section 308-07B .
7. Using the Input Shaft Oil Seal Remover and Slide Hammer, remove the output shaft seal.

Installation
RWD vehicles
1. Position a new output shaft seal.
2. Using the Rear Seal 4X2 Installer, install the output shaft seal.
3. Install the output shaft flange.
4. Install the extension housing flange seal and a new output shaft flange nut.
After installing the new output shaft flange nut, it must be staked at the slots to prevent it
from coming loose.
5. Install the rear driveshaft. For additional information, refer to Section 205-01 .

4WD vehicles
6. Install the seal protector provided with the new output shaft seal on the output shaft.
7. Slide the output shaft seal over the output shaft seal protector onto the output shaft. Remove the
output shaft seal protector.
8. Using the Rear Seal 4X4 Installer, install a new output shaft seal.
9. Install the transfer case. For additional information, refer to Section 308-07B .
All vehicles
10. Fill and check the transmission fluid. For additional information, refer to Transmission Fluid Level



6R80 Manual
Manual Control Lever Shaft and Seal
Special Tool(s)
Installer, Shifter Fluid Seal

307-559
Material
Item Specification
XT-10-QLVC
Removal
100-02 .
2. If equipped, remove the heat shield.
3. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the selector lever cable bracket.
Move the locking tab up and disconnect the transmission selector lever cable end from the manual
control lever.
passenger side front portion of the transmission case. Removal of the transmission fluid fill plug will
relieve any vacuum that might have built up in the transmission. This will aid in allowing the
transmission fluid pan to be easily removed when the bolts are removed.
Manual Control Lever Shaft and Seal 2625

Remove the transmission fluid pan gasket.
7. Remove and discard the transmission fluid filter.
the connector.
9. Pull the release tab and pull down on the bulkhead connector retainer.

bulkhead connector. Electrostatic discharge may occur and may cause damage to the
mechatronic unit.
With the bulkhead connector release tab down, pull the outer shell of the bulkhead connector out of
the mechatronic assembly.
mechatronic unit. Electrostatic discharge may occur and may cause damage to the mechatronic
unit.
Pull the bulkhead connector out of the transmission.
12. NOTICE: During removal of the mechatronic assembly, the thermal bypass valve will fall out of
the transmission case. Damage to the valve will occur if the valve falls out.
Remove the 11 bolts from the mechatronic assembly and remove the mechatronic assembly and the
bypass valve.

13. Remove the park rod actuating plate.
14. Remove the manual control lever.

1. Remove the roll pin.
2. Slide the manual control lever shaft out of the case.
3. Hold the spacer to keep it from falling out of the case.
4. Remove the manual valve inner lever and the park rod as an assembly.
15. Remove and discard the manual control lever seal.
Installation
1. Position a new manual control lever seal in place.

2. Using the Shifter Fluid Seal Installer, install a new manual control lever shaft seal.
3. Install the manual lever in the case.

1. Slide the manual lever in the case.
2. Position the spacer in place while sliding the manual lever into the spacer.
3. Position the manual valve inner lever while sliding the manual lever and lining up the roll pin
hole.
4. Install the roll pin.
4. Position the park rod in place. Push down on the park pawl and position the park rod in place.
5. While holding the park rod down, install the park rod actuating plate.
6. NOTE: Before installing the mechatronic assembly into the transmission case, verify presence and
correct orientation of the thermal bypass valve, pump adapter seal and center support seals. Also note
that one or more of the center support seals may have remained in the mechatronic assembly during
removal and should be installed into the transmission case at this time.
Verify the 4 rubber feed tubes for the center support are in place.
1. Black feed tubes

2. Green feed tube
3. Blue feed tube

7. Verify the rubber adapter is in place.
8. Coat the thermal bypass valve with petroleum jelly to hold it in place and install the thermal bypass
valve in the transmission case.
mechatronic unit. Electrostatic discharge may occur and may cause damage to the mechatronic
unit.
Position the mechatronic assembly in place and loosely install the 11 bolts.
1. Align the manual valve and control lever linkage.
10. Tighten the mechatronic bolts in the sequence shown.


11. NOTICE: Do not touch the electrical connector pins. Electrostatic discharge may occur and will
cause damage to the mechatronic unit.
With the bulkhead connector release tab down and unlocked, push the outer shell of the bulkhead
connector into the transmission. Make sure that the bulkhead connector is fully seated into the
mechatronic assembly.
12. Press up on the tab and lock the outer shell of the bulkhead connector in place.
13. Install a new transmission fluid filter.
Install a new transmission fluid pan gasket, if necessary.

lock it in place.
NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever. Pull back on the selector lever cable end to make
sure that the selector lever cable end is securely installed onto the manual control lever.
Install the selector lever cable end onto the manual control lever.
18. Lock the selector lever cable lock tab.
19. If equipped, install the heat shield.

20. Make sure the transmission fluid is at the correct level, follow the steps for Adding Additional


6R80 Manual
Transmission Insulator and Retainer
Transmission Insulator and Retainer Rear Wheel Drive (RWD)

1 9L34 Transmission insulator and retainer
2 W711140 Transmission insulator and retainer bolt
3 N621945 Transmission insulator and retainer nut
Transmission Insulator and Retainer Four-Wheel Drive (4WD)

1 9L34 Transmission insulator and retainer
2 W711140 Transmission insulator and retainer bolt
3 N621945 Transmission insulator and retainer nut
Removal
All vehicles
Transmission Insulator and Retainer 2634

100-02 .
2. Remove the RH exhaust heat shield bolt from the transmission crossmember.
3. Remove the LH exhaust heat shield bolt from the transmission crossmember.
4. Remove the 2 transmission insulator and retainer nuts.
5. Remove the LH isolator cap bolt.
6. Remove the Evaporative Emission (EVAP) canister front bracket bolt from the transmission
crossmember.
7. Position a suitable high-lift transmission jack under the transmission.
8. Remove the 4 transmission crossmember bolts (2 each side) and remove the transmission
crossmember.
Transmission Insulator and Retainer Four-Wheel Drive (4WD) 2635

9. Remove the 3 transmission insulator and retainer bolts and remove the transmission insulator and
retainer.
10. If equipped, remove the 4 skid plate bolts and remove the skid plate.
11. Remove the RH exhaust heat shield bolt from the transmission crossmember.
12. Remove the LH exhaust heat shield bolt from the transmission crossmember.
13. NOTE: Index-mark the driveshaft to maintain initial driveshaft balance for installation.
Remove the front driveshaft. For additional information, refer to Section 205-01 .

15. Remove the LH insulator cap bolt.
16. NOTE: Right side shown, left side similar. Transmission crossmember removed for clarity.
Remove the 4 transmission insulator and retainer bolts.
17. Support the transfer case.
18. Remove the 4 transmission crossmember nuts and bolts.
19. Remove the transmission insulator and retainer.
Installation
RWD vehicles
1. Install the transmission insulator and retainer and the 3 bolts.

2. Install the transmission crossmember and the 4 transmission crossmember nuts and bolts (2 each
side).
3. Install the Evaporative Emission (EVAP) canister front bracket bolt to the transmission crossmember.
4. Lower the transmission onto the transmission crossmember and install the 2 transmission insulator
and retainer nuts.
5. Install the LH isolator cap bolt.

6. Install the LH exhaust heat shield bolt to the transmission crossmember.


7. Install the RH exhaust heat shield bolt to the transmission crossmember.

4WD vehicles
8. Loosely install the transmission insulator and retainer and the 4 bolts.
9. Position the transmission crossmember and loosely install the 2 transmission insulator and retainer
nuts.
10. Install the 4 transmission support crossmember bolts and nuts.

Tighten the transmission insulator and retainer bolts to 90 Nm (66 lb-ft).
Tighten the transmission crossmember bolts and nuts to 90 Nm (66 lb-ft).
Tighten the transmission insulator and retainer nuts to 115 Nm (85 lb-ft).
11. Install the bolt for the LH isolator cap bolt bracket.

12. Install the LH exhaust heat shield bolt to the transmission crossmember.
13. Install the RH exhaust heat shield bolt to the transmission crossmember.
14. NOTE: Align the index-marks made during removal.
Install the front driveshaft. For additional information, refer to Section 205-01 .
15. If equipped, install the skid plate and the 4 skid plate bolts.



6R80 Manual
Transmission - Four Wheel Drive (4WD)
Special Tool(s)
Retainer, Torque Converter

307-346 (T97T-7902-A)
Removal
NOTE: Refer to the Transmission Cooler Flushing Job Aid on the FMCDealer website.
t="1">
With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 .
Section 418-01 .
4. NOTE: If transmission disassembly or installation of a new transmission is necessary, drain the

transmission fluid.
Remove the transmission fluid pan and allow the transmission fluid to drain.
6. Remove the transfer case. For additional information, refer to Section 308-07B .
7. NOTE: Make sure the transmission jack makes contact on the outer ribs of the transmission fluid pan.
NOTE: Make sure the transmission is securely fastened to the transmission jack.
Transmission - Four Wheel Drive (4WD) 2642

Position a suitable high-lift transmission jack under the transmission and remove the jackstand.
Disconnect the RH and LH Heated Oxygen Sensor (HO2S) and the Catalyst Monitor Sensor (CMS)
Remove the RH and LH exhaust flange nuts.
10. Remove the 2 dual converter Y-pipe bolts and the dual converter Y-pipe.
11. Remove the fuel line bracket bolt and position the fuel line bracket and lines aside.

12. If equipped, remove the heat shield from the selector lever cable.
Move the locking tab up and disconnect the selector lever cable end from the manual control lever.
14. Remove the selector lever bracket bolts and remove the selector lever bracket.
15. Remove the flexplate inspection cover bolts and the flexplate inspection cover.
16. Remove the rubber torque converter nut access plug.

17. Remove and discard the 4 flexplate-to-torque converter nuts.
18. Remove and discard the transmission fluid cooler tube bracket bolt.
19. Remove the transmission case bolt.
20. Remove the transmission fluid cooler tube bracket nut and position the transmission fluid cooler tube
bracket and tubes aside.
21. Remove the plastic starter motor electrical connector cap.

22. Remove the starter motor electrical connectors.
23. Remove the ground wire from the stud.
24. Remove the 3 starter motor bolts and the starter motor.
25. Disconnect the wiring harness from the top of the transmission.
the connector.

27. NOTE: The top 2 transmission case bolts need to be removed prior to removing the remaining bolts.
NOTE: The top left bolt secures the fuel line bracket to the transmission case.
Remove the 6 remaining transmission case bolts.
28. Slide the transmission back enough to install the Torque Converter Retainer.
29. Remove the transmission from the vehicle.
30. If the transmission is to be overhauled or if installing a new transmission, carry out the Transmission
Fluid Cooler Backflushing and Cleaning procedure. For additional information, refer to Transmission
Fluid Cooler Backflushing and Cleaning in this section.



6R80 Manual
Transmission - Rear Wheel Drive (RWD)
Special Tool(s)

307-346 (T97T-7902-A)
Removal
NOTE: Refer to the Transmission Cooler Flushing Job Aid on the FMCDealer website.
t="1">
Disconnect the battery ground cable. For additional information, refer to Section 414-01 .
Section 418-01 .
3. Remove the driveshaft. For additional information, refer to Section 205-01 .
4. NOTE: If transmission disassembly or installation of a new transmission is necessary, drain the

transmission fluid.
Remove the transmission fluid pan and allow the transmission fluid to drain.
6. If equipped, remove the heat shield from the selector lever cable.
Transmission - Rear Wheel Drive (RWD) 2649

Move the locking tab up and disconnect the selector lever cable end from the manual control lever.
8. Remove the selector lever cable bracket bolts and remove the selector lever cable bracket.
9. Remove the flexplate inspection cover bolts and the flexplate inspection cover.
10. Remove the rubber torque converter nut access plug.
11. Remove and discard the 4 flexplate-to-torque converter nuts.

12. Remove and discard the transmission fluid cooler tube bracket bolt.
13. Remove the transmission case bolt.
14. Remove the transmission fluid cooler tube bracket nut and position the transmission fluid cooler tube
bracket and tubes aside.
15. Remove the plastic starter motor electrical connector cap.
16. Remove the starter motor electrical connectors.

17. Remove the ground wire nut from the stud and remove the ground wire.
18. Remove the 3 starter motor bolts and the starter motor.
19. Remove the RH exhaust heat shield bolt.
20. Remove the LH exhaust heat shield and Evaporative Emission (EVAP) canister bolts.
Disconnect the RH and LH Heated Oxygen Sensor (HO2S) and the Catalyst Monitor Sensor (CMS)

22. Remove the fuel line bracket bolt and position the fuel line bracket and fuel lines aside.
23. NOTE: Make sure the transmission jack makes contact on the outer ribs of the transmission fluid pan.
Position a suitable high-lift transmission jack under the transmission.
25. Remove the LH isolator cap bolt.
26. Remove the Evaporative Emission (EVAP) canister front bracket bolt from the transmission
crossmember.
27. Remove the transmission crossmember.

1. Remove the 4 transmission crossmember bolts and nuts.

2. Remove the transmission crossmember.
28. Remove the 3 transmission insulator and retainer bolts and remove the transmission insulator and
retainer.
Remove the RH and LH exhaust flange nuts.
30. Remove the 2 dual converter Y-pipe bolts and the dual converter Y-pipe.
31. Disconnect the wire harness from the top of the transmission.

the connector.
33. NOTE: The top 2 transmission-to-engine bolts need to be removed prior to removing the remaining
bolts.
NOTE: The top left bolt secures the fuel line bracket to the transmission case.
Remove the 6 remaining transmission case bolts.
34. Slide the transmission back far enough to install the Torque Converter Retainer.
35. Remove the transmission from the vehicle.

36. If the transmission is to be overhauled or if installing a new transmission, carry out the Transmission
Fluid Cooler Backflushing and Cleaning procedure. For additional information, refer to Transmission
Fluid Cooler Backflushing and Cleaning in this section.


6R80 Manual
DISASSEMBLY Procedure revision date: 08/12/2010
Transmission
Special Tool(s)
Handle, Torque Converter

307-091 (T81P-7902-C)

307-003 (T57L-500-B)
Installer, Front Wheel Hub Oil Seal

205-256
Remover, Input Shaft Oil Seal

308-375
Remover, Needle Bearing

307-562 (includes 307-562/1 and
307-562/2)
Remover, Pilot Bearing
308-001 (T58L-101-B)

307-553
Retaining Ring Pliers

307-343 (T95P-77001-AHR)
Slide Hammer
100-001 (T50T-100-A)
All vehicles
1. Install Transmission Holding Fixture 307-003 on the torque converter housing and install the
transmission on a bench.
2. Using the Torque Converter Handle 307-091, remove the torque converter.
Transmission 2657
3. Remove the transmission fluid pan bolts and the pan.
5. Remove and discard the transmission fluid filter.
6. Press the release tab and lift up on the bulkhead connector retainer to release the bulkhead connector
shell.
Transmission 2658
Transmission Control Module (TCM). Electrostatic discharge may occur and may cause
With the transmission bulkhead connector retainer up, pull the outer shell of the bulkhead connector
out of the transmission.
8. Remove the 11 bolts from the mechatronic assembly.
9. Remove the mechatronic assembly.
10. Remove the rubber adapter and the fluid filter seal.
11. Remove and discard the 4 rubber feed tubes for the center support. Note the size and location while
removing for correct installation.
1. Black feed tubes
2. Green feed tube
Transmission 2659
3. Blue feed tube
12. Remove the thermal bypass valve from the case.
13. Inspect the thermal bypass valve for damage, install a new valve if damage is indicated.
14. Using the Input Shaft Oil Seal Remover 308-375 and Slide Hammer 100-001, remove and discard the
front pump seal.
15. Remove and discard the 13 front pump bolts.
Transmission 2660
16. Using the Transmission Fluid Pump Remover 307-553 and Slide Hammer 100-001, remove the front
pump support.
17. Inspect the back of the front pump to check if the selective shim is on the pump. If the selective shim
is on the pump, remove it from the pump.
18. Remove and discard the front pump O-ring seal from the pump assembly.
19. If the selective shim is not on the pump, using a magnet, remove it from the forward/overdrive clutch
assembly.
Transmission 2661
20. Remove the forward (clutch A)/overdrive (clutch E) clutch assembly.
21. Remove the caged T5 roller bearing.
22. Remove the direct clutch assembly.
23. Using the Retaining Ring Pliers 307-343, remove the center support snap ring.
24. Remove the center support and T6 bearing.
25. NOTE: If the thrust bearing stuck to the back of the center support during removal, remove the thrust
bearing from the center support.
Remove the selective shim from the center support.
Transmission 2662
26. NOTE: If the selective shim stuck to the T7 thrust bearing during removal of the center support,
remove the shim from the thrust bearing.
If the selective shim is stuck to the T7 thrust bearing, remove the shim and remove the thrust bearing.
27. NOTE: When removing the planet carrier and the low/reverse clutch pack, some of the clutch plates
may stay in the case. Remove any clutch plates from the transmission that were not removed with the
carrier and keep the clutch plates together.
Remove the planet carrier and the low/reverse clutch pack as an assembly.
28. Remove the low/reverse sun gear.
29. NOTE: When removing the sun gear, take note that the taper edge is facing up toward the torque
converter housing.
Remove the sun gear from the planet assembly.
Transmission 2663
30. NOTE: Remove the bearings with the sun gear.
Remove the top T8 and the bottom T9 roller bearings from the sun gear.
31. Remove the T9 roller bearing race in the bottom of the carrier.
32. If the T10 thrust bearing is attached to the rear planetary carrier, remove it from the carrier. If it
stayed in the transmission case when the rear planetary carrier was removed, remove it from the
transmission case.
33. NOTICE: The output shaft flange nut has been staked to prevent it from coming loose. Prior to
removing the nut, remove the stake to prevent damage to the output shaft.
Remove and discard the output shaft flange nut.
Transmission 2664
34. Remove the extension housing flange seal and the output shaft flange.
35. Remove the planet carrier hub, output shaft assembly and T11 bearing.
36. Using a suitable tool, remove the output shaft seal.
37. Remove the slip plane washer.
38. Remove the thrust bearing.
Transmission 2665
39. Using the Pilot Bearing Remover 308-001, remove the thrust bearing spacer.
40. Install the Needle Bearing Remover 307-562/1 on the bearing.
41. Install the Front Wheel Hub Oil Seal Installer 205-256 on the Needle Bearing Remover 307-562/1
and remove the bearing.
42. Remove the planet carrier hub, output shaft assembly and T11 bearing.
43. Remove and discard the output shaft seal.
Transmission 2666
44. Remove the snap ring from the case.
45. NOTICE: Use care when installing the Needle Bearing Remover 307-562. Look inside the
transmission case to make sure that the Needle Bearing Remover 307-562 contacts the bearing
only and not the lip of the case, or damage to the case will occur.
Using the Needle Bearing Remover 307-562 and the Front Wheel Hub Oil Seal Installer 205-256,
remove the bearing assembly.
All vehicles
46. Remove the park rod actuating plate.
47. Remove the manual control lever detent plate and park pawl actuator rod.
1. Remove the roll pin.
2. Slide the manual control lever shaft out of the case.
3. Hold the manual control lever spacer to keep it from falling into the case.
Transmission 2667
4. Remove the manual control lever detent plate and park pawl actuator rod as an assembly.
48. Using a suitable tool, remove and discard the manual control lever seal.
49. Remove the bolt from the back of the case to gain access to the park pawl pin.
50. From the inside of the case, push the park pawl pin out toward the back side of the case while holding
the spring and the park pawl. Remove the park pawl pin then remove the park pawl and spring.
1. Park pawl pin
2. Park pawl spring
3. Park pawl
51. Remove the 2 bolts and the park detent spring.
Transmission 2668
Transmission 2669

6R80 Manual
SUBASSEMBLIES
Forward/Overdrive Clutch Assembly - Disassembly
Special Tool(s)
End Play Gauge, Clutch

307-555
Material
Item Specification
Motorcraft ME Automatic MERCON
Transmission Fluid LV
XT-10-QLVC
Disassembly
1. Position the forward/overdrive clutch assembly in the Clutch End Play Gauge 307-555.
2. Index-mark the direct clutch outer shell snap ring gap location to the side of the forward clutch hub
using a suitable paint marker.
1. Index mark
2. Snap ring gap
Forward/Overdrive Clutch Assembly - Disassembly 2670

3. NOTICE: Compress the snap ring out of the groove 180 degrees from the snap ring gap or
damage to the forward clutch hub can occur.
Using a suitable tool, remove and discard the direct clutch outer shell retaining ring by compressing
the snap ring 180 degrees from the snap ring gap.
1. Snap ring gap

2. 180 degrees from the snap ring gap
4. Remove and discard he direct clutch hub.
5. Remove the forward clutch hub and sun shaft assembly.
6. NOTE: The bearing may stick in the forward clutch drum.
Remove the intermediate shaft bearing.

7. Remove the intermediate shaft assembly.
8. If the T3 thrust bearing stuck to the intermediate shaft assembly, remove it from the intermediate shaft
assembly. If the T3 thrust bearing is on the overdrive clutch, remove it from the overdrive clutch
assembly.
9. Remove the overdrive clutch pack from the forward clutch pack.



6R80 Manual
SUBASSEMBLIES
Forward Clutch Assembly
Special Tool(s)
Compressor, Clutch Spring

307-525


307-555
Material
Item Specification
XT-10-QLVC
Forward Clutch Assembly (A Clutch)
Part
1 7A360 Forward clutch drum
2 7A548 Forward clutch piston outer O-ring seal
3 7A548 Forward clutch piston inner O-ring seal
Forward Clutch Assembly 2674

5 7A480 Forward clutch piston return spring

6 7A548 Forward clutch balance dam O-ring seal
7 7H360 Forward clutcalance dam
8 7H365 Forward clutch balance dam retaining ring
9 7H579 Sun gear retaining ring
10 7D063 Sun gear
11 7H375 Bearing (T1)
12 7A398 Planetary gear
13 7E085 Forward clutch cushion spring
14 7E314 Forward clutch external splined steel plates (quantity
model dependent)
15 7B164 Forward clutch internal splined friction plates (quantity
model dependent)
17 7D483 Forward clutch plate retaining ring
Disassembly
NOTE: Clutch plate quantity is model dependant based on engine displacement:
4.6L engine (Explorer, Mountaineer, Sport Trac, F-150)

Four friction plates
Five steel plates
5.4L engine (Expedition, Navigator, F-150)
Five friction plates
Six steel plates
1. If the T2 thrust bearing is on the forward clutch assembly, remove it from the forward clutch
assembly.
2. Remove the front planetary carrier and sun gear from the forward clutch assembly.
With a small screwdriver or a suitable pick inserted into the front planetary assembly, push on
the retaining ring in 4 places while lifting up on the front planetary assembly.
Forward Clutch Assembly (A Clutch) 2675

3. Remove the forward clutch pack snap ring.
4. NOTE: Inspect the forward clutch drum and the friction and steel plates for damage. Install new
Remove and inspect the forward clutch steel and friction plates.
If the plates are damaged, install a new forward clutch assembly.

If no damage is indicated, the forward clutch may be reassembled.
5. For correct alignment during assembly, make an identifying mark on the balance dam and the center
part of the housing.
6. NOTE: The bottom of the Clutch Spring Compressor 307-525 will need to be installed from the back
side of the forward clutch assembly.

Using the Clutch Spring Compressor 307-525, slightly collapse the balance dam to gain access to the
retaining ring and remove the retaining ring.
7. Remove the balance dam.
8. Remove and discard the O-ring seal from the balance dam.
9. Remove the forward clutch return spring.
10. Install the forward clutch on the front pump to remove the forward clutch piston. Apply a small
amount of shop air to remove the piston.

11. Remove and discard the inner and outer piston O-ring seals.
12. Remove the sun gear from the planet assembly.
13. NOTE: The T1 thrust bearing may have stuck to the sun gear when it was removed.
Remove the T1 bearing from the planetary carrier.
14. Remove the transmission fluid collector plate from the front planetary carrier.

15. Clean and inspect the components of the forward clutch assembly for damage and install new
Assembly
1. NOTE: If a new planetary assembly is being installed, the new planetary assembly may not come
with the snap ring installed.
Install the planetary assembly snap ring, if necessary.
2. Make sure the planetary snap ring is oriented as shown.
3. Install the transmission fluid collector plate on the front planetary carrier.
4. Install the T1 bearing onto the sun gear.

5. Install the sun gear into the planet assembly with the T1 bearing facing down and the recessed part of
the gear up.
6. Install new O-ring seals onto the forward clutch piston.
7. Lightly coat the O-ring seals with clean transmission fluid and install the forward clutch piston into
the forward clutch drum.
8. Install the forward clutch return spring.
9. Install a new O-ring seal onto the forward clutch balance dam. Lightly coat the O-ring seal with clean
transmission fluid.

10. Align the marks made during disassembly and install the balance dam into the forward clutch drum.
11. NOTE: Prior to releasing the Clutch Spring Compressor 307-525, make sure that the snap ring is
fully seated.
Using the Clutch Spring Compressor 307-525, slightly collapse the balance dam to install the
retaining ring. Install the retaining ring.
12. NOTE: Friction and steel plate quantity will vary based on engine displacement. For additional
information, refer to the Clutch Plate Quantity Chart in the Specifications portion of this section.
Soak the new forward clutch plates in clean transmission fluid.
13. Install the new forward clutch plates, starting with the wave spring then a steel plate and alternating
between friction and steel plates and install the pressure plate.
14. Install the forward clutch plate snap ring.

15. NOTE: All forward clutch plates, friction and steel are of a wave-type design.
Install the forward clutch assembly into the Clutch End Play Gauge 307-555 and install the Dial
Indicator Gauge with Holding Fixture 100-002 and position the plunger so it fits into the opening of
the snap ring.
16. With the Dial Indicator Gauge set at zero, lift up on the steel pressure plate so it is against the select
fit snap ring. Record this reading as reading A.
17. Rotate the forward clutch assembly 180 degrees from the opening of the snap ring, take a second
reading and record this reading as reading B.
Description Reading
Reading A
Reading B
Add reading A to reading B for a total end clearance
Divide the total reading by 2 for an average end clearance
18. NOTE: If the final measurement is not within specification, install a new snap ring until the correct
specification is achieved.
5.4L engine - 0.71-1.10 mm (0.028-0.043 in).

4.6L engine - 0.71-1.10 mm (0.028-0.043 in).
If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate is
high, remeasure using a thicker select fit snap ring. If the free pack end clearance between the bottom
of the snapg and the top of the pressure plate is low, remeasure using a thinner select fit snap ring.
19. Install the sun gear and planetary gearset into the forward clutch drum. Make sure it snaps and locks
in place.

20. Install the T2 thrust bearing.


6R80 Manual
SUBASSEMBLIES
Overdrive Clutch Assembly
Special Tool(s)
Compressor, Spring Washer

307-209


307-555
Material
Item Specification
XT-10-QLVC
Overdrive (O/D) Clutch Assembly

1 7F207 Input shaft
2 7A548 Overdrive (O/D) clutch piston outer seal
3 7A548 O/D clutch piston inner seal
4 7A262 O/D clutch piston
5 7B070 O/D clutch piston spring
6 7A548 O/D balance piston outer sea
7 7H360 O/D balance piston
8 7C122 O/D balance piston snap ring
Overdrive Clutch Assembly 2684

9 7B164 O/D clutch internal splined clutch plates (friction)

10 7B442 O/D clutch external splined clutch plates (steel)
11 7B066 O/D pressure plate
12 7D483 O/D clutch retaining ring
13 7C096 Bearing T3
Disassembly
1. Position the Overdrive (O/D) clutch assembly in the Clutch End Play Gauge 307-555 and remove the
T3 thrust bearing.
2. Remove the O/D clutch pack snap ring.
3. Remove the O/D clutch pack.
4. Using the Spring Washer Compressor 307-209 and a press, remove and discard the O/D clutch
balance piston retaining ring.
5. Remove the O/D clutch balance piston.
Overdrive (O/D) Clutch Assembly 2685

6. Remove the O/D clutch return spring.
7. Remove the O/D clutch apply piston.
8. Remove and discard the outer O-ring seal on the O/D clutch balance piston.
9. Remove and discard both the inner (one large and one small) O-ring seals on the O/D clutch apply
piston.
10. Remove and discard the 3 scarf cut seals.

Assembly
1. Install the 3 new scarf cut seals and the roller bearing.
2. Install a new outer O-ring seal on the O/D clutch balance piston.
3. Install 2 new inner O-ring seals on the O/D clutch apply piston.
4. Lubricate all the O-ring seals with clean transmission fluid. Install the O/D clutch apply piston into
the drum with the O-ring seals and the 3 pads facing down toward the drum.
5. NOTE: The fingers on the return spring are facing down toward the piston.
Install the O/D clutch return spring.

6. NOTE: The cone shape of the balance piston must face up when installed correctly.
Lubricate all the O-ring seals with clean transmission fluid. Install the O/D clutch balance piston.
7. Using the Spring Washer Compressor 307-209, install a new O/D clutch balance piston retaining ring.
8. Soak the new O/D clutch plates in clean transmission fluid.
9. Install the new O/D clutch plates, starting with a steel plate and alternating between friction and steel
plates, and ending with the pressure plate on the top.
10. Install the O/D clutch pack snap ring.

11. NOTE: All O/D clutch plates, friction and steel are of a wave-type design.
Install the O/D clutch assembly into the Clutch End Play Gauge 307-555 and install the Dial Indicator
Gauge with Holding Fixture 100-002 and position the plunger so it fits into the opening of the snap
ring.
13. Rotate the O/D clutch assembly 180 degrees from the opening of the snap ring, take a second reading
and record this reading as reading B.
Description Reading
Reading A
Reading B
5.4L engine - 0.5-0.9 mm (0.019-0.035 in).

4.6L engine - 0.5-0.9 mm (0.019-0.035 in).
of the snap ring and the top of the pressure plate is low, remeasure using a thinner select fit snap ring.
15. NOTE: Inspect and install new thrust bearings as required.
Install the T3 thrust bearing.



6R80 Manual
SUBASSEMBLIES
Forward/Overdrive Clutch Assembly - Assembly
Special Tool(s)

307-555
Material
Item Specification
Motorcraft MERCONtic MERCON
Transmission Fluid LV
XT-10-QLVC
Assembly
1. Position the forward clutch assembly in the Clutch End Play Gauge 307-555 and install the overdrive
clutch pack onto the forward clutch and planetary gear set.
2. Install the intermediate shaft assembly.
3. NOTE: Inspect and install new thrust bearings as required.
Install the T4 intermediate shaft bearing.
Forward/Overdrive Clutch Assembly - Assembly 2691

4. Install the forward clutch hub and sun shaft assembly.
5. Installa new the direct clutch hub.
6. NOTICE: Do not install the snap ring on the forward clutch hub with the snap ring gap in the
same position as the original snap ring or damage to the transmission can occur.
Install a new direct clutch outer shell retaining ring with the snap ring gap positioned approximately
120 degrees from the index mark made on the forward clutch hub during disassembly.
1. New snap ring gap

2. Index mark from original snap ring gap



6R80 Manual
SUBASSEMBLIES
Direct Clutch Assembly
Special Tool(s)

307-015 (T65L-77515-A)

307-552


307-555
Material
Item Specification
XT-10-QLVC
Direct Clutch Assembly
Part
2 7B066 Direct clutch pressure plate (quantity model dependant)
Direct Clutch Assembly 2694

3 7B164 Direct clutch internal splined friction plates (quantity

model dependant)
4 7B442 Direct clutch external splined steel plates
5 - Direct clutch cushion plate (wave spring)
6 7C096 Bearing (T5)
7 7A577 Piston retaining ring
8 7A262 Direct clutch balance piston
9 7A548 Direct clutch balance piston seal
10 7B488 Return spring
11 7A262 Direct clutch apply piston
12 7A548 Direct clutch apply piston outer seal
13 7C099 Direct clutch apply piston inner seal
14 - Direct clutch bushing hubs (part of 7F283) (2 required)
15 - Gear shaft tube sleeve (part of 7F283)
17 7D020 Seal shell cylinders
Disassembly

Five steel plates
Six steel plates
1. Remove and discard the 2 scarf cut seals and the roller bearing.
2. Remove the T5 thrust bearing.
3. Remove the direct clutch snap ring.

4. Remove the direct clutch steel and friction plates.
5. Install the Clutch Spring Compressor 307-552 and the Clutch Spring Compressor 307-015 onto the
direct clutch assembly.
6. Using the Clutch Spring Compressor 307-552 and Clutch Spring Compressor 307-015, compress the
direct clutch return spring and remove the direct clutch return spring retainer.
7. Remove the Clutch Spring Compressor 307-552 and the Clutch Spring Compressor 307-015.
8. Remove the balance piston.

9. Remove the direct clutch return spring.
10. Remove the direct clutch piston.
11. Remove and discard the outer O-ring seal from the balance piston.
12. Remove and discard the outer and inner O-ring seals from the apply piston.
13. Inspect the components of the direct clutch for damage. If damage is indicated, install new

Assembly
1. Install a new inner and outer O-ring seal on the apply piston.
2. Install a new outer O-ring seal on the balance piston.
3. Lightly coat the O-ring seals in clean transmission fluid and install the direct clutch piston.
4. Install the direct clutch return spring.
5. Install the balance piston.
6. Install the Clutch Spring Compressor 307-552 and the Clutch Spring Compressor 307-015 onto the
direct clutch assembly.

7. Using the Clutch Spring Compressor 307-552 and the Clutch Spring Compressor 307-015, compress
the direct clutch return spring and install the direct clutch return spring retainer.
Soak the new direct clutch in clean transmission fluid.
9. Install the new direct clutch plates, starting with the wave spring then a steel plate and alternating
between steel and friction plates, and ending with the pressure plate on the top.
10. Install the direct clutch snap ring.
11. NOTE: Inspect and install a new thrust bearing as required.
Install the T5 thrust bearing.

12. NOTE: All direct clutch plates, friction and steel are of a wave-type design.
Install the direct clutch assembly into the Clutch End Play Gauge 307-555 and install the Dial
the snap ring.
14. Rotate the direct clutch assembly 180 degrees from the opening of the snap ring, take a second
Description Reading
Reading A
Reading B
5.4L engine - 0.5-1.3 mm (0.019-0.051 in).

4.6L engine - 0.5-1.3 mm (0.019-0.051 in).
16. Install 2 new scarf cut seals and the roller bearing.



6R80 Manual
SUBASSEMBLIES
Intermediate Clutch Assembly
Special Tool(s)

307-525


307-555
Material
Item Specification
XT-10-QLVC
Intermediate Clutch Assembly
Part
2 7D483 Intermediate clutch pack retaining ring
4 7B164 Intermediate clutch internal splined friction plates
(quantity model dependent)
Intermediate Clutch Assembly 2702

5 7B442 Intermediate clutch external splined steel plates (quantity

model dependent)
6 7E085 Intediate clutch cushion spring
7 7A577 Intermediate clutch snap ring
8 7B043 Intermediate clutch return spring retaining ring
9 7A480 Intermediate clutch piston return spring
11 7F225 Intermediate clutch piston inner seal
12 7F224 Intermediate clutch piston outer seal
13 7F373 Bearing (T6)
14 - Intermediate/low/reverse clutch center support
15 7G199 Center support seals (2 - 7G199, 1 - 7G087, 1 - 7G484)
Disassembly

Four steel plates
Five steel plates
1. Remove the T6 thrust bearing.
2. Remove the intermediate clutch plate snap ring.
3. Remove the intermediate clutch plates.

4. Using the Clutch Spring Compressor 307-525, remove and discard the intermediate clutch return
spring retainer.
5. Remove the intermediate clutch return spring top plate.
6. Remove the intermediate clutch return spring.
7. Applying a slight amount of air to the port, remove the intermediate clutch piston.
8. Remove and discard the inner and outer intermediate clutch piston O-ring seals.

Assembly
1. Install new inner and outer intermediate clutch piston O-ring seals.
2. Lightly coat the O-ring seals in clean automatic transmission fluid and install the intermediate clutch
piston.
3. Install the intermediate clutch return spring.
4. Install the intermediate clutch return spring top plate.
5. Using the Clutch Spring Compressor 307-525, install a new intermediate clutch return spring retainer.
Soak the new intermediate clutch plates in clean automatic transmission fluid.

7. Install the new intermediate clutch plates, starting with the wave spring then a steel plate and
alternating between friction and steel plates, and ending with the pressure plate.
8. Install the intermediate clutch plate snap ring.
9. NOTE: All intermediate clutch plates, friction and steel are of a wave-type design.
Install the intermediate clutch assembly into the Clutch End Play Gauge 307-555 and install the Dial
the snap ring.
11. Rotate the intermediate clutch assembly 180 degrees from the opening of the snap ring, take a second

Description Reading
Reading A
Reading B
5.4L engine - 0.7-1.1 mm (0.027-0.043 in).

4.6L engine - 0.7-1.1 mm (0.027-0.043 in).


6R80 Manual
SUBASSEMBLIES
Low/Reverse Clutch Assembly
Special Tool(s)

307-525
Depth Micrometer
303-D075 (D92P-4201-A) or equivalent


307-555
Gauge, D-Clutch Measurement

307-554
Material
Item Specification
XT-10-QLVC
Low/Reverse Clutch Assembly
Item Description
Low/Reverse Clutch Assembly 2708

Part
Number
1 - Intermediate/low/reverse clutch center support
2 7B220 Center support keys (2 required)
3 7F225 Low/reverse clutch piston center seal
4 7D404 Low/reverse clutch cylinder inner seal
5 7D403 Low/reverse clutch cylinder outer seal
6 7A262 Low/reverse clutch piston
7 7B070 Low/reverse clutch return spring
8 - Washer
9 7D483 Low/reverse clutch return spring retainer
10 7E085 Low/reverse clutch cushion spring
11 7B164 Low/reverse clutch internal splined friction plates
(internal to case)
12 7B442 Low/reverse clutch external splined steel plates (internal
to case)
13 7B066 Low/reverse clutch pressure plate (internal to case)
(select fit)
Disassembly
NOTE: The low/reverse clutch plates are installed in the case during the Assembly procedure.
1. Remove the T7 thrust bearing and the shim from the center support.
2. Using the Clutch Spring Compressor 307-525, remove and discard the low/reverse clutch return
spring retainer.
3. Remove and discard the low/reverse clutch return spring washer.

4. Remove the low/reverse clutch return spring.
5. Apply a slight amount of air to the port, remove the low/reverse clutch piston from the low/reverse
clutch drum.
6. Remove and discard the low/reverse outer piston O-ring seals.
7. Remove and discard the low/reverse drum O-ring seals.

Assembly
Low/reverse piston
1. Install new low/reverse outer piston O-ring seals.
2. Install new low/reverse drum O-ring seals.
3. Lubricate the O-ring seal with clean automatic transmission fluid and install the low/reverse piston.
4. Install the low/reverse clutch return spring.

5. Install a new low/reverse clutch return spring washer.
6. Using the Clutch Spring Compressor 307-525, compress the low/reverse clutch return spring and
install the retaining ring.
7. Install the shim and the T7 thrust bearing on the center support.
Low/reverse clutch stackup
8. NOTE: All intermediate clutch plates, friction and steel are of a wave-type design.
Install the D-Clutch Measurement Gauge 307-554 into the case.

9. With the D-Clutch Measurement Gauge 307-554 positioned in the case, use the Depth Micrometer
303-D075 to measure the case stop depth.
Description Reading
Measure the distance from the top of the upper gauge bar to the top of the lower gauge bar.
Record this reading as the case measurement. Record as reading A.
10. Measure the clutch pack height.
Description Reading
Place the low/reverse clutch pack on the Clutch End Play Gauge 307-555 with the wave
spring down and the pressure plate on top. Using the Dial Indicator Gauge with Holding
Fixture 100-002, place the plunger on the pressure plate. Slide the clutch to the side so the
plunger of the Dial Indicator is touching the gauge plate of the Clutch End Play Gauge
307-555. Zero out the Dial Indicator Gauge.
Carefully lift the plunger enough to slide the clutch pack under the plunger to take a
reading. Record this reading. Rotate the clutch pack 180 degrees and take a second reading.
Add the first and second readings together and divide the total by 2. Record this reading as
B.

11. Using the Depth Micrometer 303-D075, measure the piston to center support shoulder height.
Description Reading
Measure the piston to center support shoulder height. Record this measurement. Rotate the
center support 180 degrees and record this measurement. Add the first and the second
measurements, then divide by 2. Record this as reading C.
12. Calculate the end clearance.
Description Reading
Subtract B and C from A to determine end clearance
Total C measurement
End clearance specification 1.0-1.6 mm
(0.039-0.062 in)
Compare the end clearance to the specification. If the end clearance is out of specification, select the
next thinner or thicker plate as required and repeat Steps 10, 11 and 12.



6R80 Manual
SUBASSEMBLIES
Material
Item Specification
XT-10-QLVC
Mechatronic

1 7A100 Transmission Control Module
(TCM)
2 - Transmission control valve
body (upper)
3 7E195 Transmission control valve
check ball (8 required)
4 7Z490 Transmission control
valve body separator plate
body (lower)
6 -

Transmission control valve

assembly
7 7H187 Transmission control filter
assembly
8 7B155 Transmission fluid filter
9 7J191 Transmission solenoid damper
valve assembly
10 W707886 Mechatronic assembly bolt -
connects upper and lower half
together (19 required)
11 W707884 Mechatronic assembly bolt -
connects TCM to transmission
control valve assembly (6
required)
12 - Transmission shift control
solenoids
Mechatronic Upper Half
Part
1 7A092 Transmission control valve assembly (ditch plate)
(upper half)
2 7E195 Transmission control valve check ball (8 required)
3 - Transmission clutch D2 latch valve
4 - Trach valve spring
5 - Transmission clutch valve spring plug
6 7G007 Transmission clutch valve spring plug retainer clip
7 - Transmission clutch D2 regulator valve
8 - Transmission clutch valve spring
12 - Transmission clutch B regulator valve
Mechatronic 2717

15 - Transmission clutch valve
Mechatronic Lower Half
Part
assembly (lower half)
solenoid hold-down bracket
solenoid hold-down bracket
bolt M5 x 0.80 x 12
4 7G484 Transmission shift control
solenoid
Mechatronic Upper Half 2718


spring
6 - Transmission clutch A
latch valve
7 - Transmission spring
retainer plate
spring
9 - Transmission clutch B latch
valve
10 7F194 Transmission spring
retainer plate
11 7G383 Electronic Pressure Control
(EPC) solenoid
12 - Transmission solenoid
regulator valve spring
pressure regulator valve
14 - Transmission solenoid plug
15 7G007 Transmission valve plug
retainer
16 - Transmission clutch D1
latch valve
spring
Transmission drive enable
20 - valve
valve spring
retainer
multiplex valve
valve spring
retainer
spring
29 - Transmission clutch A
30 - Transmission clutch
regulator valve sleeve
31 - Transmission valve return
plug
Mechatronic Lower Half 2719


plug
return clip
spring
35 - Transmission clutch E
plug
return clip
38 - Transmission clutch E latch
valve
39 - Transmission clutch control
valve spring
40 - Transmission 41 7G007 Transmission
valign="top"> valve plug
return clip
42 - Transmission bypass clutch
control valve spring
43 - Transmission bypass clutch
control valve
plug
return clip
46 - Transmission manual oil
spring
47 - Transmission main oil
48 - Transmission manual oil
sleeve
return clip
50 - Transmission converter
regulator valve
51 - Transmission converter
regulator valve spring
plug
return clip
54 - Transmission lube control
valve
55 - Transmission lube control
valve spring
Mechatronic Lower Half 2720


plug
return clip
58 W527007-S Retaining ring
59 - Transmission control
manual valve
Check Ball Location
Item Description
1 Reverse/drive control check ball
2 Shift solenoid control check ball
3 Intermediate clutch exhaust control check ball
4 Direct clutch exhaust control check ball
5 Low/reverse clutch exhaust control check ball
6 Forward clutch exhaust control check ball
7 Overdrive (O/D) clutch exhaust control check ball
8 Reverse exhaust control check ball
9 Clutch exhaust valve
10 Converter drain back valve
11 Large screen
12 Small screen
Disassembly
NOTICE: Do not touch the electrical connector pins or the exposed solenoid tabs on the Transmission
Control Module (TCM). An electrostatic discharge may occur and may cause damage to the TCM
/mechatronic assembly.
NOTE: Make an identifying mark on each solenoid and the corresponding bore for correct assembly.
NOTE: Solenoids may visually appear the same but their designs/functions are different. Caution must be
taken not to assemble the mechatronic assembly incorrectly. Incorrect solenoid installation will result in poor
transmission shift quality.
Check Ball Location 2721

NOTE: Note where the 8 check balls, 2 solenoid dampers, 2 internal valves and springs and 2 internal filters
are located for reassembly.
Mechatronic assembly upper half
1. Make an identifying mark on each solenoid and the corresponding bore for correct assembly.
2. Remove the 6 long bolts from the Transmission Control Module (TCM) unit.
3. Carefully separate the TCM from the mechatronic assembly.

1. TCM
4. Remove 19 short bolts from the mechatronic assembly.
5. Separate the lower half of the mechatronic assembly from the upper half of the mechatronic assembly.

6. Remove and discard the separator plate.
7. Remove the solenoid dampers, check balls, converter drain back valve and filter screens from the
mechatronic assembly. Note the location for assembly. Refer to the preceding exploded views.
1. Solenoid dampers
2. Check balls
3. Converter drain back valve
4. Small screen
5. Big screen
8. Remove the clips, caps, valves and springs from each bore of the mechatronic assembly. Note the
location and order for assembly. Refer to the preceding exploded views.
9. Using clean mineral spirits, clean the upper half of the mechatronic assembly.
Mechatronic assembly lower half

10. Remove the 8 solenoid bracket bolts and the solenoid bracket.
11. Remove the solenoids.
12. Remove the clips, caps, valves and springs from each bore of the mechatronic assembly. Note the
location and order for assembly. Refer to the preceding exploded views.
13. Using clean mineral spirits, clean the lower half of the mechatronic assembly.
Assembly
NOTICE: Do not touch the electrical connector pins or the exposed solenoid tabs on the Transmission
Control Module (TCM). An electrostatic discharge may occur and may cause damage to the TCM
/mechatronic assembly.
Mechatronic assembly upper half
1. NOTE: Many components and surfaces in the mechatronic valve body are precision machined.
Careful handling during disassembly, cleaning, inspection and assembly will prevent unnecessary
damage to machined surfaces.
Install the clips, caps, valves and spring into each bore. Refer to the preceding exploded views.

Mechatronic assembly lower half
2. NOTE: Many components and surfaces in the mechatronic valve body are precision machined.
Careful handling during disassembly, cleaning, inspection and assembly will prevent unnecessary
damage to machined surfaces.
Install the clips, caps, valves and spring into each bore.
3. NOTE: Lubricate the O-ring seals of the solenoids with clean automatic transmission fluid when
installing them into the valve body.
Install the solenoids into their correct bores as indicated during disassembly.
4. Install the solenoid bracket and the 8 bolts.


5. NOTICE: Towards the back of the upper valve body there is a hydraulic passage that is shaped
as though it receives a check ball. This passage does not require a check ball. Be sure not to
mistake this hydraulic passage for a passage that does require a check ball or damage to the
transmission can occur.
Install the solenoid dampers, check balls, converter drain back valve and filter screens.
1. Solenoid dampers
2. Check balls
3. Converter drain back valve
4. Small screen
5. Big screen
6. Empty hydraulic passage (no check ball)
6. Align the guide pins on the TCM with the holes in the upper valve body and install the valve body on
the TCM .
1. TCM
2. Upper valve body
3. Guide pins

7. NOTICE: The separator plates are different between the early and late build mechatronic
assemblies to accommodate the different number of dampers. Failure to install the correct
separator plate can result in harsh, soft or erratic shifts or damage to the transmission.
NOTICE: If the drain back valves are not installed correctly in the separator plate, damage to
the transmission can occur.
Position the separator plate on the upper valve body.

Check the 2 drain back valves to be sure they are correctly positioned in the separator plate when the
separator plate is pressed flush against the upper valve body.
1. Separator plate
2. Drain back valves
8. Position the lower valve body on the 2 TCM alignment studs, align the manual valve with the
Transmission Range (TR) sensor on the TCM and install the lower valve body.
1. Lower valve body
2. Manual valve
3. TR sensor

9. Install the 6 (long) TCM -to-valve body bolts hand-tight.
10. Install the 19 (short) mechatronic assembly lower-to-upper valve body bolts.
Tighten the bolts in the sequence shown.
Tighten bolts 1 through 6 in the tightening sequence to 7 Nm (62 lb-in).
Tighten bolts 7 through 25 in the tightening sequence to 6 Nm (53 lb-in).



6R80 Manual
SUBASSEMBLIES
Pump Assembly
Special Tool(s)
Installer, Fluid Pump Seal

307-556
Material
Item Specification
Motorcraft
MERCON Item Part Number Description
LV Automatic 1 7A248 Front pump oil
Transmission seal
Fluid
XT-10-QLVC 2 - Pump body (part
of 7A103)
3 7A248C Pump body seal
4 7A103 Pump plate
assembly
5 7A248A Pump plate
assembly seal
6 W707871-S300 Pump plate
assembly-to-front
pump body bolt
(11 required)
7 7D019 Clutch support
fluid seal
8 7L323 Front pump
support seal
Disassembly
1. Remove the front pump washer.
2. If the O-ring seal was not

removed during disassembly,
remove and discard the front
Pump Assembly 2730

pump O-ring seal from the pump

assembly.
3. Remove and discard the front

pump seal rings from the stator
support.
4. Index-mark the pump body to

the pump plate assembly.
1. Pump body
2. Pump plate assembly
3. Index mark
5. Remove the 11 pump plate

assembly-to-pump body bolts.
6. Push down on the loose pump

plate assembly-to-pump body
bolts to remove the pump body
from the pump plate assembly
and remove the 11 bolts.
Pump Assembly 2731

7. Remove the fluid pump gears.
8. Remove and discard the pump

body outer seal.
9. Inspect the inner and the outer

pump gears for damage.
Clean all pump
components in solvent.
Dry the parts with
compressed air.
Inspect the pump gears,
faces, gear teeth and
mating surfaces for
damage or scoring.
Install a new pump as
necessary.
Pump Assembly 2732

10. Inspect the pump body and

pump plate thrust surfaces for
damage or scoring.
1. Pump body
3. Pump gear thrust
surfaces
11. Inspect the torque converter hub

bearing for damage or scoring.
Make sure that the bearing
rotates smoothly.
Assembly
1. NOTE: Prior to installation,

lightly lubricate the pump gears
with clean automatic
transmission fluid.
Install the pump gears with the

dot facing the pump plate
assembly.
Pump Assembly 2733

2. Install a new pump body outer

seal.
3. Align the marks made during

disassembly to correctly
assemble the pump. Press the
pump body into the pump plate
assembly. Visually inspect the
pump body-to-pump plate
assembly bolt holes to be sure
that the pump body and pump
plate are correctly aligned.
1. Pump body
3. Pump gear thrust
surfaces
4. Install the pump plate

assembly-to-front pump body
bolts.
Tighten to 15 Nm (133
lb-in).
5. NOTICE: Make sure that the
Pump Assembly 2734

seal ends of each seal ring are

hooked together or fluid
leakage can occur.
Install the 2 front pump seal

rings onto the stator support.
Make sure the seals are fully
seated in the stator support seal
grooves and the seal ends are
oriented 180 degrees apart.
6. Install the pump outer diameter

front pump O-ring seal.
7. Install a new front pump seal on

the Fluid Pump Seal Installer
307-556.
8. Using the Fluid Pump Seal

Installer 307-556, install the
front pump seal.
9. NOTE: Lightly lubricate the

thrust washer with petroleum
Pump Assembly 2735

jelly to hold it in place during

assembly.
Install the pump thrust washer.
Pump Assembly 2736


6R80 Manual
ASSEMBLY Procedure revision date: 08/12/2010
Transmission
Special Tool(s)

100-002 (TOOL-4201-C)
Drawbar (Heavy Duty Threaded)

204-029 (T77F-1176)
Handle, Torque Converter

307-091 (T81P-7902-C)
Installer, Rear Seal 4X4

307-637
Installer, Fluid Pump Seal

307-556
Installer, Front Wheel Hub Oil Seal

205-276 (T88T-1175-AH)
Installer, Output Shaft Bearing

307-647
Installer, Shifter Fluid Seal

307-559
Rear Seal Installer 4X2

307-638
Remover/Installer, Rear Bearing

307-639

307-553
Retaining Ring Pliers

307-343 (T95P-77001-AHR)
Transmission 2737
Material
Item Specification
XT-10-QLVC
CRC SL3151
Disassembled Views
Disassembled Views 2738


1 N800750-S437 Flexplate-to-torque converter nut (4 required)

2 7902 Torque converte/td>
3 7A103 Pump assembly
4 7A248 Front pump oil seal
5 - Pump body (part of 7A103)
6 7A248 Front pump inner oil seal
7 7N134 Front pump-to-case bolt (13 required)
8 7A103 Front pump assembly
9 W707871-S300 Bolt - attaches pump to pump adapter assembly (11
required)
10 7A248 Front pump outer oil seal
11 7D019 Clutch support fluid seal
12 7L323 Front pump support seal
13 - Forward clutch assembly (clutch A)
14 - Forward clutch rear bushing (part of 7A360)
15 7D014 Front pump selective washer
16 7A360 Forward clutch cylinder and hub assembly
17 7A548 Forward clutch inner piston seal
18 7A548 Forward clutch outer piston seal
20 7A480 Forward clutch piston retaining spring
21 7H360 Forward clutch balance piston assembly
22 7A548 Forward clutch balance piston outer seal
23 7H365 Forward clutch balance piston snap ring
24 7E085
25 7E314 Forward clutch steel plates (externally splined)
26 7B164 Forward clutch friction plates (internally splined)
28 7D483 Pressure plate retaining snap ring
29 7D063 Front planetary sun gear (No. 1)
31 - Front planetary carrier assembly snap ring (part of
7A398)
33 7L339 Plate transmission fluid collector
34 7L495 Bearing (T2)
35 - Overdrive (O/D) clutch assembly (clutch E)
36 7G091 Turbine shaft seals (3 required)
37 7F207 Input shaft
38 - Fluid distributor sleeve (part of 7J006)
39 - Output shaft bushing (part of 7J006)
40 7A548 O/D clutch piston outer seal

41 7A548 O/D clutch piston inner seal

42 7A262
43 7B070 O/D clutch piston spring
44 7A548 Balance piston outer seal
45 7H360 O/D balance piston
46 7C122 Balance piston snap ring
47 7B442 O/D clutch steel plates (externally splined)
48 7B164 O/D clutch friction plates (internally splined)
49 7B066 O/D pressure plate
50 7D483 O/D clutch retaining ring
52 7F351 Intermediate clutch shaft
54 - Sun gear bushings (part of 7R193) (2 required)
55 7B067 Sun gear hub and shaft assembly
56 7F236 Direct clutch hub
57 7C122 Direct clutch cylinder retaining ring
59 - Direct clutch assembly (clutch B)
60 7B066 Direct clutch pressure plate
61 7B164 Direct clutch friction plates (internally splined)
62 7B442 Direct clutch steel plates (externally splined)
63 7E085 Direct clutch cushion plate
65 7A577 Direct clutch piston retaining ring
66 7A262 Direct clutch balance piston
67 7A548 Direct clutch balance seal
68 7B488 Direct clutch piston return spring
69 - Direct clutch piston
70 7A548 Direct clutch piston outer seal
71 7C099 Direct clutch piston inner seal
72 - Direct clutch hub bushings (part of 7F283) (2
required)
73 - Gear shaft tube sleeve (part of 7F283)
75 7D020 Shell cylinder seals (2 required) tr>
77 - Intermediate clutch assembly (clutch C)
78 7D483 Intermediate clutch pressure plate retaining ring
80 7B442 Intermediate clutch steel plates (externally splined)

81 7B164 Intermediate clutch friction plates (internally splined)

82 7E085 Intermediate clutch pressure plate spring
83 7A577 Intermediate clutch retaining ring
84 7B043 Intermediate clutch ring
85 7A480 Intermediate clutch piston spring
87 7F225 Intermediate clutch piston inner seal
88 7F224 Intermediate clutch piston outer seal
89 7F373 Bearing (T6)
90 - Center shaft sleeve (part of support assembly)
91 7B220 Center support keys (2 required)
92 7G199 Center support seals (4 required)
93 - Support assembly
94 7F225 Low/reverse clutch piston center seal
95 7D404 Low/reverse clutch piston inner seal
97 7A262 Low/reverse clutch piston
98 7B070 Low/reverse clutch piston return spring
99 7C122 Retainer transmission-snap ring
100 7D483 Low/reverse clutch piston retaining ring
101 7E085 Clutch disc cushion plate
102 7B442 Low/reverse clutch steel plates (externally splined)
103 7B164 Low/reverse clutch friction plates (internally splined)
104 7B066 Low/reverse clutch pressure plate (select fit)
105 7F405 Thrust gear shim (select fit)
107 7D063 Sun gear No. 2
108 7D235 Thrust bearing outer race
109 7D234 Bearing (T8)
110 7D063 Sun gear No. 3
111 7D234 Bearing (T9)
112 - Bearing race (T9)
114 - Fluid collar rear planetary plate (part of 7D006)
115 7A153 Output shaft ring gear assembly
116 7G178 Bearing (T10)
117 7B256 Output shaft bushing (part of 7060)
Output shaft park gear assembly (Rear Wheel Drive
118 7060
(RWD))
119 7060 Output shaft park gear assembly (Four-Wheel Drive
(4WD))
120 7N194 Output shaft retaining ring
121 7B368 Bearing (T11)
122 7005 Transmission case assembly (model dependent)

123 7A010 Transmission case fluid fill plug assembly

124 7H398 Transmission case fluid fill plug
125 7A010 Transmission case fluid fill seal
126 7A010 Transmission oil level indicator
127 7034 Transmission case vent assembly (model dependent)
128 7A415 Output shaft bearing assembly ( RWD )
129 7A415 Output shaft bearing assembly ( 4WD )
130 7A433 Washer
131 7B368 Bearing (T12)
132 7030 Output shaft bearing snap ring 4WD
133 7N357 Slip plane washer
134 7052 Extension housing seal ( RWD )
135 7052 Extension housing seal ( 4WD )
136 7089 Output shaft flange ( RWD )
138 7045 Output shaft flange retaining nut ( RWD )
139 7E332 Manual valve detent spring
140 W711235-S300
Manual valve detent spring retaining screw and
washer
141 7A232 Park pawl actuating rod
142 7A441 Park pawl
143 7D070 Park pawl return spring
144 7D071 Park pawl shaft
145 7H398 Plug assembly transmission case housing
146 7G101 Park rod actuating plate
147 W711235-S300 Park pawl abutment retaining screw and washer
148 W708455-S441 Manual control lever nut
150 7B498 Manual control lever shaft seal
151 7C493 Manual control lever shaft
152 7A209 Manual control lever shaft spacer
153 7A115 Manual valve detent lever assembly
154 7G100 Manual valve detent lever retaining pin
155 7H322 Thermal bypass valve
156 7F401 Front pump adapter seal
157 7A100 Main control assembly
158 - Main control valve body assembly (part of 7A100)
159 7Z490 Main control valve body separator plate
160 - Lower main control valve body (part of 7A100)
161 - Transmission Control Module (TCM) (part of
7A100)
162 7G276 Bulkhead connector sleeve
163 - Transmission fluid filter seal (part of 7A098)
164 7A098 Transmission fluid filter

165 - Transmission fluid pan magnet

166 7A191 Transmission fluid pan gasket
167 7A194 Transmission fluid pan
168 W500214-S437 Transmission fluid pan bolt

Five ste
Six steel plates
All vehicles
1. Install the detent spring and the 2 bolts.

2. Position the park pawl and spring into the case and install the park pawl pin.
1. Park pawl
2. Park pawl spring
3. Park pawl pin
3. Install the park pawl pin bolt.


4. Install a new manual control lever shaft seal on the Shifter Fluid Seal Installer 307-559.
5. Using the Shifter Fluid Seal Installer 307-559, install the manual control lever shaft seal.
6. Assemble the manual valve detent lever assembly and park pawl actuator rod.
7. Position the detent lever and park pawl actuator rod in the transmission case.
8. Position the manual control lever spacer in place and slide the manual control lever shaft in the case
and into the manual lever detent plate.
1. Manual control lever spacer
2. Manual control lever shaft
3. Manual control lever detent plate

9. Align the roll pin hole in the manual control lever detent plate with the roll pin hole in the manual
control lever shaft and install a new roll pin using a suitable tool.
10. Install the park rod actuating plate and the 4 bolts.
11. If removed, position a new bearing on Needle Bearing Installer 307-647. Install the bearing with the
flat bearing surface facing down and the rounded bearing surface facing up so that when installed, the
flat surface is on the snap ring side and the rounded surface is on the transmission case side.
1. Rounded bearing surface facing up
2. Flat bearing surface facing down
12. Using the Needle Bearing Installer 307-647, the Drawbar 204-029 and the Front Wheel Hub Oil Seal
Installer 205-276, install the bearing in the transmission case.

14. Install the bearing on the Rear Bearing Remover/Installer 307-639.
15. Assemble the Front Wheel Hub Oil Seal Installer 205-276 and the Rear Bearing Remover/Installer
307-639 on the Drawbar 204-029 and install the bearing in the transmission case.

16. Remove the Front Wheel Hub Oil Seal Installer 205-276, the Rear Bearing Remover/Installer 307-639
and the Drawbar 204-029.
17. Position the thrust bearing spacer in place.
18. Using the Needle Bearing Installer 307-558 and a press, press the thrust bearing spacer in place.
20. Install the slip plane washer.

All vehicles
21. Place the transmission in the vertical position.
22. Install the T11 bearing, planet carrier hub and output shaft assembly.
4WD vehicles
23. Position a new output shaft seal in place.
24. Using the Rear Seal 4X4 Installer 307-637, install the output shaft seal.
RWD vehicles
25. Position a new output shaft seal on the Rear Seal Installer 4X2 307-638.
26. Using the Rear Seal Installer 4X2 307-638, install the output shaft seal.

27. Install the output shaft flange and the extension housing flange seal.
28. Loosely install a new output shaft flange nut.
All vehicles
29. Install the T10 bearing and silver shim (caged bearing) on the planet carrier hub and output shaft
assembly.
30. Install the T9 roller bearing race in the bottom of the carrier.
31. Install the top T8 and the bottom T9 roller bearings onto the sun gear.
32. NOTE: When installing the sun gear, make sure that the taper edge is facing up toward the torque
converter housing.
Install the sun gear into the planet assembly.

33. Install the low/reverse sun gear and race in the planet carrier.
34. Install the planet carrier.
35. Soak the new low/reverse clutch plates in clean automatic transmission fluid.
36. Install the low/reverse clutch plates, starting with the pressure plate and alternating between the
friction and steel plates and ending with the wave spring plate on the top.
37. NOTE: Inspect and install a new thrust bearing as required.
Install the low/reverse thrust bearing T7 and the select fit thrust gear shim.

38. NOTE: Make sure that when installing the center support the feed holes on the center support are
lined up with the feed holes in the case.
Install the center support into the case.
39. NOTE: Rotate the case to a horizontal position.
Using the Retaining Ring Pliers 307-343, install the center support snap ring. Using a suitable tool, be
sure the snap ring is fully seated.
RWD vehicles
40. Install the Dial Indicator Gauge with Holding Fixture 100-002 on the transmission case and position
the plunger on the output shaft flange.
41. Using the Dial Indicator Gauge with Holding Fixture 100-002, lift up on the output shaft flange and
record the reading. The reading should be within 0.15-0.35 mm (0.005-0.013 in).

If the reading is not within the specification, install a different (either thinner or thicker) select
fit thrust gear shim.
42. Tighten the output shaft flange nut.

After installing the new output shaft flange nut, stake the slots to prevent it from coming
loose.
4WD vehicles
43. Install the Dial Indicator Gauge with Holding Fixture 100-002 on the transmission case and position
the plunger on the output shaft.
44. Using the Dial Indicator Gauge with Holding Fixture 100-002, lift up on the output shaft and record
the reading. The reading should be within 0.15-0.35 mm (0.005-0.013 in).
If the reading is not within the specification, install a different (either thinner or thicker) select
fit thrust gear shim.

All vehicles
46. Install the direct clutch drum.
47. Install the T5 bearing on the direct clutch assembly.
48. Install the forward and overdrive clutch assembly.
49. Install the selective pump washer.
50. If the front pump assembly was not disassembled and assembled, install a new front pump outer
diameter O-ring seal and lubricate it with petroleum jelly.

51. Install a new front pump seal on the Fluid Pump Seal Installer 307-556.
52. Using the Fluid Pump Seal Installer 307-556, install the front pump seal.
53. Install the Transmission Fluid Pump Remover 307-553 on the front pump.
54. Lubricate the transmission case pump bore with petroleum jelly. Using the Transmission Fluid Pump
Remover 307-553, position the pump assembly in the case and rotate the pump to insert the pump
splines into the front planetary sun gear. Rotate the pump to align the pump-to-case bolts and push the
pump into the case.

55. Remove the Transmission Fluid Pump Remover 307-553.
56. Install new front pump bolts with new washers. Tighten the bolts in a crisscross pattern.
57. Install the Transmission End Play Gauge 307-534 on the input shaft to measure the end play.
Tighten the wing nut.
58. Install the Dial Indicator Gauge with Holding Fixture 100-002 on the Transmission End Play Gauge
307-534.
Push down on the Transmission End Play Gauge 307-534 and zero out the Dial Indicator
Gauge.
Lift up on the Transmission End Play Gauge 307-534 and record the measurement on the Dial
Indicator Gauge. The measurement should be between 0.2-0.4 mm (0.008-0.015 in). If the
measurement is not within specification, install a new selective front pump washer.
Measure the original washer, install a thinner or a thicker washer to achieve the correct
measurement.
59. Remove the Dial Indicator Gauge with Holding Fixture 100-002 and the Transmission End Play
Gauge 307-534.

60. Install the 4 rubber feed tubes for the center support.
1. Black feed tubes
2. Green feed tube
3. Blue feed tube
61. NOTE: Make sure that the fluid filter seal has been removed. If it has not, use a suitable pick and
remove the seal.
NOTE: Add 0.118L (4 oz) of clean transmission fluid to prime the pump.
Install the rubber adapter and prime the fluid pump.
62. Install the thermal bypass valve into the case.
63. Align the mechatronic assembly guide pins in the alignment holes in the transmission case and
position the mechatronic assembly in place.
1. Alignment holes

2. Guide pins
64. NOTE: The mechatronic assembly will not lay flush on the case, this is a normal condition with the
rubber feed tubes, the bolts will pull the mechatronic assembly down.
Slightly lift the mechatronic assembly and align the manual valve in the manual valve linkage and
position the mechatronic assembly in place.
Install the mechatronic assembly bolts and tighten the bolts in the sequence shown.
With the release tab up and unlocked, push the outer shell of the bulkhead electrical connector into the
transmission. Make sure that the bulkhead connector is fully seated into the TCM .

67. Press down on the tab and lock the outer shell of the bulkhead electrical connector in place. Make
sure that the locking tab is securely locked.
68. Install a new transmission fluid filter.
69. NOTE: The fluid pan gasket can be reused if not damaged.
Install a new transmission fluid pan gasket if required.
70. Install the fluid pan and tighten the bolts in a crisscross pattern.
71. Using the Torque Converter Handle 307-091, install the torque converter. Remove the Torque
Converter Handle 307-091.



6R80 Manual
Transmission - Four Wheel Drive (4WD)
Special Tool(s)

307-346 (T97T-7902-A)

Material
Item Specification
XT-10-QLVC
CRC SL3151
Installation
1. NOTICE: Prior to the installation of the transmission, the torque converter pilot hub must be
lubricated with multi-purpose grease or damage to the torque converter or engine crankshaft
can occur.
Lubricate the torque converter pilot hub with multi-purpose grease.
2. Install the Torque Converter Retainer.

3. NOTICE: The converter housing is piloted into position by dowels in the rear of the engine
block. The torque converter must rest squarely against the flexplate. This indicates that the
converter pilot is not binding in the engine crankshaft.
NOTE: Make sure the transmission jack makes contact on the outer ribs of the transmission fluid pan.
Position and secure the transmission on the high-lift transmission jack. Raiseposition the transmission
into the vehicle.
4. Remove the Torque Converter Retainer.
5. NOTE: Make sure the torque converter is fully seated in the transmission before aligning the
transmission to the engine.
With the transmission in a horizontal position, move it toward the engine. Align the orange balancing
marks between the torque converter studs and the flexplate bolt holes.
6. NOTE: Install the transmission case bolts in their correct locations noted during removal.
NOTE: The top 2 transmission case bolts need to be installed prior to installing the remaining bolts.
NOTE: The top left bolt is inserted through the fuel line bracket first, then through the transmission
case.
Install 6 of the remaining 7 transmission case bolts.
lock it in place.

8. Connect the wire harness to the top of the transmission.
9. Install the starter motor and the 3 starter motor bolts.

10. Install the ground wire on the stud and install the ground wire nut.
11. Install the starter motor electrical connectors.

1. Tighten to 12 Nm (106 lb-in).
12. Install the plastic starter motor electrical connector cap.

13. Position the transmission fluid cooler tubes in place and install the transmission fluid cooler tube
bracket front stud bolt nut.
14. Align the transmission fluid cooler tube bracket and install the remaining transmission case bolt.
15. NOTE: Inspect the case and make sure the old transmission fluid cooler tube O-rings are not stuck in
the case.
NOTE: Install new transmission fluid cooler tube O-rings on the ends of the transmission fluid cooler
tubes prior to installing.
Install new transmission fluid cooler tube O-rings on the transmission fluid cooler tubes.
16. Install the transmission fluid cooler tubes and the transmission fluid cooler tube bracket bolt.

17. Install 4 new flexplate-to-torque converter nuts.
18. Install the rubber access plug.
19. Install the flexplate inspection cover and the inspection cover bolts.
20. Install the selector lever cable bracket and selector lever cable bracket bolts.
21. NOTE: When installing the selector lever cable end, make sure that the selector lever cable end is
correctly installed onto the manual control lever. Pull back on the selector lever cable to make sure the
selector lever cable end is securely installed onto the manual control lever.
NOTE: Apply pressure to the selector lever cable end while connecting it to the manual control lever
to make sure the selector lever has not moved out of the DRIVE position.
Connect the selector lever cable to the manual control lever.
Listen for the audible click.

Pull back on the selector lever cable to make sure that the selector lever cable is securely
installed.

23. Install the selector lever cable heat shield.
24. Install the fuel line bracket and the fuel line bracket bolt.
25. NOTICE: Prior to installation, inspect the Heated Oxygen Sensor (HO2S) and the Catalyst
Monitor Sensor (CMS) wiring harness for damage.
Position the dual converter Y-pipe in place and install the 2 dual converter Y-pipe bolts.
Install the LH and RH exhaust flange nuts.

Connect the RH and LH HO2S and the CMS electrical connectors.
28. Position a jackstand under the transmission, and remove the transmission jack.
29. Install the transfer case. For additional information, refer to Section 308-07B .
31. Verify that the selector lever cable is correctly adjusted. For additional information, refer to Section
307-05 .
32. Restore the module configuration. Carry out the module configuration restore steps of the
Programmable Module Installation (PMI) procedure for the PCM. For additional information, refer to

Section 418-01 .
33. Fill the transmission with automatic transmission fluid. For additional information, refer to
34. After completing the repairs, use the scan tool and perform the Misfire Monitor Neutral Profile
Correction procedure, following the on-screen instructions.


6R80 Manual
Transmission - Rear Wheel Drive (RWD)
Special Tool(s)

307-346 (T97T-7902-A)

Material
Item Specification
XT-10-QLVC
CRC SL3151
Installation
1. NOTICE: Prior to the installation of the transmission, the torque converter pilot hub must be
lubricated with multi-purpose grease or damage to the torque converter or engine crankshaft
can occur.
Lubricate the torque converter pilot hub with multi-purpose grease.
2. Install the Torque Converter Retainer.

3. NOTICE: The converter housing is piloted into position by dowels in the rear of the engine
block. The torque converter must rest squarely against the flexplate. This indicates that the
converter pilot is not binding in the engine crankshaft.
NOTE: Make sure the transmission jack makes contact on the outer ribs of the transmission fluid pan.
Position and secure the transmission on the high-lift transmission jack. Raiseposition the transmission
into the vehicle.
4. Remove the Torque Converter Retainer.
5. NOTE: Make sure the torque converter is fully seated in the transmission before aligning the
transmission to the engine.
With the transmission in a horizontal position, move it toward the engine. Align the orange balancing
marks between the torque converter studs and the flexplate bolt holes.
6. NOTE: Install the transmission case bolts in their correct locations noted during removal.
NOTE: The top 2 transmission case bolts need to be installed prior to installing the remaining bolts.
NOTE: The top left bolt is inserted through the fuel line bracket first, then through the transmission
case.
Install 6 of the remaining 7 transmission case bolts.
lock it in place.

8. Connect the wire harness to the top of the transmission.
9. NOTICE: Prior to installation, inspect theHeated Oxygen Sensor (HO2S) and theCatalyst
Monitor Sensor (CMS) wiring harness for damage.
Position the dual converter Y-pipe in place and install the 2 dual converter Y-pipe bolts.
Install the LH and RH exhaust flange nuts.
11. Position the transmission insulator and retainer to the transmission and install the 3 transmission
insulator and retainer bolts.

12. Position the transmission crossmember in place and loosely install the transmission insulator and
retainer nuts.
13. Install the transmission crossmember.

1. Install the transmission crossmember.
2. Install the 4 transmission crossmember bolts and nuts.
14. Tighten the transmission insulator and retainer nuts.

15. Install the LH isolator cap and bolt.

16. Install the Evaporative Emission (EVAP) canister front bracket bolt to the transmission crossmember.

17. Install the fuel line bracket and fuel line bracket bolt.
Connect the RH and LH HO2S and the CMS electrical connectors.
19. Install the LH exhaust heat shield and Evaporative Emission (EVAP) canister bolts.
20. Install the RH exhaust heat shield bolt.

21. Position the starter motor in place and install the 3 starter motor bolts.

22. Install the ground wire on the stud and install the ground wire nut.
23. Install the starter motor electrical connectors.

24. Install the plastic starter motor electrical connector cap.
25. Position the transmission fluid cooler tubes in place and install the transmission fluid cooler tube
bracket nut.
26. Align the transmission fluid cooler tube bracket and install the remaining transmission case bolts.

27. NOTE: Inspect the case and make sure the old transmission fluid cooler tube O-rings are not stuck in
the case.
NOTE: Install new transmission fluid cooler tube O-rings on the ends of the transmission fluid cooler
tubes prior to installing.
Install new transmission fluid cooler tube O-rings on the transmission fluid cooler tubes.
28. Install the transmission fluid cooler tubes and the transmission fluid cooler tube bracket bolt.
29. Install 4 new flexplate-to-torque converter nuts.

30. Install the rubber access plug.
31. Install the flexplate inspection cover and the flexplate inspection cover bolts.

32. Install the selector lever cable bracket and selector lever cable bracket bolts.
correctly installed onto the manual control lever. Pull back on the selector lever cable to make sure the
selector lever cable end is securely installed onto the manual control lever.

installed.
35. If equipped, install the selector lever cable heat shield.

36. Install the driveshaft. For additional information, refer to Section 205-01 .
38. Verify that the selector lever cable is correctly adjusted. For additional information, refer to Section
307-05 .
39. Restore the module configuration. Carry out the module configuration restore steps of the
Programmable Module Installation (PMI) procedure for the PCM. For additional information, refer to
Section 418-01 .
40. Fill the transmission with automatic transmission fluid. For additional information, refer to
41. After completing the repairs, use the scan tool and perform the Misfire Monitor Neutral Profile
Correction procedure, following the on-screen instructions.

SECTION 307-02: Transaxle/Transmission Cooling 2011 Expedition, Navigator Workshop Manual

Material

Capacity
Motorcraft MERCON LV MERCON -
XT-10-Q
Engine mount nuts 175 129
Sway bar bracket nuts 55 41
Transmission fluid cooler tube bracket bolt at transmission 48 35
Transmission fluid cooler tube bracket bolt 25 18
Transmission fluid cooler tube bracket nut 40 30


Transmission Cooling
The transmission fluid cooling system consists of:
transmission fluid cooler inlet and outlet tubes.

an in-tank transmission fluid cooler inlet tube.
a non-repairable in-tank transmission fluid cooler.
an auxiliary transmission fluid cooler inlet tube (HD).
an auxiliary transmission fluid cooler (HD).
an auxiliary transmission fluid cooler outlet tube (HD).
The transmission fluid flows from the transmission to the in-tank transmission fluid cooler, to the auxiliary
transmission fluid cooler and returns to the transmission.
For Transmission Fluid Cooler Backflushing and Cleaning, refer to Section 307-01 .
6R80 HD with Towing Package

1 8005 Radiator
2 7R081 Transmission fluid cooler inlet and outlet tubes
3 7Z465 Transmission fluid cooler tube secondary latches
4 7B028A Transmission fluid cooler inlet hose
5 7C410 Auxiliary transmission fluid cooler inlet hose
6 7A095 Auxiliary transmission fluid cooler
7 7B028B Auxiliary transmission fluid cooler outlet hose
8 7C107 Transmission fluid cooler hose clamps
Transmission Cooling 2779

9 7000 Transmission
6R80 Base Package

1 8005 Radiator
5 7C410 Transmission fluid cooler outlet hose
6 7C107 Transmission fluid cooler hose clamps
7 7000 Transmission
6R80 HD with Towing Package 2780

6R80 Base Package 2781


Transmission Cooling
NOTICE: When internal wear or damage occurs in the transmission, metal particles and clutch plate
material can travel into the torque converter, the transmission fluid cooler tubes, the in-tank
transmission fluid cooler and the auxiliary transmission fluid cooler, if equipped. These contaminants
are a major cause of recurring transmission concerns. To prevent future concerns, remove these
contaminants from the cooling system before placing the transmission back into use. Refer to
Transmission Fluid Cooler Backflushing and Cleaning in Section 307-01 .
1. Visually inspect for obvious signs of mechanical damage, incorrect component installation and
system leaks. Repair as necessary.
Install a new or remanufactured radiator when transmission fluid is found leaking from the
in-tank transmission fluid cooler. Refer to Section 303-03 .
Install a new O-ring when transmission fluid is found leaking between the radiator
transmission fluid cooler and the transmission fluid cooler fitting (not the cooler tube into the
fitting). Refer to the Component Test in this section.
Install a new auxiliary transmission fluid cooler if there is leakage from the transmission fluid
cooler. Refer to Auxiliary Transmission Fluid Cooler in this section.
2. If the fault is not visually evident, GO to Symptom Chart - Transmission Cooling or GO to Symptom
Chart - NVH .
Symptom Chart - Transmission Cooling
Symptom Chart - Transmission Cooling
Symptom Chart - NVH
Symptom Chart - NVH

elimination type of diagnostic approach to pinpoint the respble system. If this is not the causal system for the
Vibration - a high frequency (20-80 Hz) that is felt through the seat or selector lever. Changes with
engine speed
Transmission cooler tubes grounded out
CHECK the transmission cooler tubes. REPAIR as necessary.

Component Test
Transmission Fluid Cooler Leaks at Radiator
Transmission fluid may leak between the radiator transmission fluid cooler and the transmission fluid cooler
fitting (not the cooler tube into the fitting), which may result in a residue of transmission fluid on the radiator
tank around the fluid cooler fitting. The in-tank transmission fluid cooler is not serviceable. If installation of a
new transmission fluid cooler is required, refer to Section 303-03 .


Auxiliary Transmission Fluid Cooler
Material
Item Specification
XT-10-QLV

1 7C107 Auxiliary transmission fluid cooler hose clamps
4 7A095 Auxiliary transmission fluid cooler
Removal
1. Remove the upper radiator cover.

2. Remove and discard the auxiliary transmission fluid cooler inlet hose clamp.
Auxiliary Transmission Fluid Cooler 2784

3. Disconnect the auxiliary transmission fluid cooler inlet hose from the cooler.
100-02 .
5. Position the flexible air deflector aside, then remove and discard the auxiliary transmission fluid
cooler outlet hose clamp.
6. Disconnect the auxiliary transmission fluid cooler outlet hose from the cooler.
7. Remove the auxiliary transmission fluid cooler.
Installation
1. Install the auxiliary transmission fluid cooler.
2. Connect the auxiliary transmission fluid cooler outlet hose to the cooler.
3. Install a new auxiliary transmission fluid cooler outlet hose clamp, then position the flexible air
deflector back into place.
4. Connect the auxiliary transmission fluid cooler inlet hose to the cooler.
5. Install a new auxiliary transmission fluid cooler inlet hose clamp.
6. Install the upper radiator cover.

1. Install the fasteners.
Section 307-01 .



Transmission Fluid Cooler Hoses
Special Tool(s)

307-569
Material
Item Specification
XT-10-QLV

2 7C107 Auxiliary transmission fluid cooler hose clamps
Removal
1. Remove the upper radiator cover.

Transmission Fluid Cooler Hoses 2787

2. Remove and discard the auxiliary transmission fluid cooler inlet hose clamps.
3. Disconnect the auxiliary transmission fluid cooler inlet hose from the coolers.
100-02 .
5. Remove the pushpin and position the air deflector aside.
6. Remove the transmission fluid cooler tube secondary latches.
7. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler hoses
from the transmission fluid cooler tubes.
8. Remove and discard the transmission fluid cooler hose clamps.
9. Disconnect the transmission fluid cooler hoses from the coolers.
Installation
1. Connect the transmission fluid cooler hoses to the coolers.
2. Install new transmission fluid cooler hose clamps.
3. Connect the transmission fluid cooler hoses to the transmission fluid cooler tubes.
4. Install the transmission fluid cooler tube secondary latches.
5. Reposition the air deflector and install the pushpin.

6. Connect the auxiliary transmission fluid cooler inlet hose to the coolers.
7. Install new auxiliary transmission fluid cooler inlet hose clamps.
8. Install the upper radiator cover.

1. Install the fasteners.
Section 307-01 .


Transmission Fluid Cooler Tubes
Special Tool(s)

307-569
Material
Item Specification
XT-10-QLV

1 N605905-S439 Transmission fluid cooler tube bracket bolt
2 - Transmission fluid cooler tube bracket bolt at
transmission
3 W707014-S441 Transmission fluid cooler tube bracket nut
6 7J227 Transmission fluid cooler O-rings (4 required)
Removal
100-02 .
Transmission Fluid Cooler Tubes 2790

2. Remove the pushpin and position the air deflector aside.
3. Remove the transmission fluid cooler tube secondary latches.
4. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes
from the transmission fld cooler hoses.
5. Remove the transmission fluid cooler tube bracket nut from the front of the engine.
6. Remove the transmission fluid cooler tube bracket bolt from the RH side of the transmission.
7. NOTE: The transmission fluid cooler tube O-rings may remain in the transmission case. Carefully
remove them from the case if retained.
Remove the transmission fluid cooler tube bracket bolt and disconnect the transmission fluid cooler
tubes from the transmission.

8. Remove and discard the 4 sway bar bracket nuts and lower the front sway bar.
9. NOTICE: Only use hand tools when removing the engine mount nuts or damage to the engine
mount may occur.
For Four-Wheel Drive (4WD) vehicles, remove the RH engine mount nuts and lift the engine
approximately 25 mm (0.984 in) to gain clearance for the transmission fluid cooler tubes.
10. Remove the transmission fluid cooler tubes from the vehicle.
Installation
1. Position the transmission fluid cooler tubes in the vehicle.
2. Position the transmission fluid cooler tube bracket to the side of the transmission and install the
transmission fluid cooler tube bracket bolt.
3. Position the transmission fluid cooler tube bracket to the front of the engine and install the nut.

4. Connect the transmission fluid cooler tubes to the transmission fluid cooler hoses.
5. Install the transmission fluid cooler tube secondary latches.
6. Reposition the air deflector and install the pushpin.
7. Position the sway bar in place and install 4 new sway bar bracket nuts.
8. NOTICE: Only use hand tools when installing the engine mount nuts or damage to the engine
mount may occur.
For 4WD vehicles, lower the engine and install the RH engine mount nuts.

9. NOTE: Inspect the case to make sure that the old transmission fluid cooler tube O-rings are not stuck
in the case.
NOTE: Install new transmission fluid cooler tube O-rings on the ends of the cooler lines prior to
installing.
Install new O-rings on the transmission fluid cooler tubes.
10. Position the transmission fluid cooler tubes into the transmission, then install the transmission fluid
cooler tube bracket bolt.
Section 307-01 .



External Controls Manual

Hood release cable lever bolts 9 - 80
Instrument panel lower reinforcement panel screws 9 - 80
Selector lever assembly-to-console bolts 8 - 71
Selector lever cable bracket bolts 25 18 -
Selector lever knob screw (floor shift) 2 - 18
Selector lever mechanism (column shift) 6 - 53
Selector lever-to-mechanism bolt (column shift) 18 - 159


External Controls
The selector lever cable transfers the transmission operating mode from the selector lever to the automatic
transmission. The indicated position of the selector lever is transferred to the transmission through the steering
column mounted selector lever, or the floor mounted selector lever, then to the cable and down to the manual
control lever on the transmission.
Brake Shift Interlock System - Column
The brake shift interlock system prevents moving the selector lever from the PARK position until the brake
pedal is applied. The brake shift interlock system consists of a Brake Shift Interlock Actuator (BSIA) mounted
at the upper end of the steering column. When the ignition switch is in the RUN position and the selector lever
is in PARK, the BSIA is energized when the brake pedal is applied. This will allow the selector lever to be
moved from the PARK position.
Brake Shift Interlock System - Floor
The brake shift interlock system prevents moving the selector lever from the PARK position until the brake
pedal is applied. The brake shift interlock system consists of a BSIA mounted on the floor selector lever.
When the ignition switch is in the RUN position and the selector lever is in PARK, the BSIA is energized
when the brake pedal is applied. This will allow the selector lever to be moved from the PARK position.
Tow/Haul Switch
The tow/haul switch is a momentary contact switch that is located on the end of the column selector lever or
on the floor selector lever knob. To activate the tow/haul feature, press the button on the end of the selector
lever or floor selector lever knob. The tow/haul feature delays upshifts to reduce frequency of transmission
shifting. tow/haul also provides engine braking in all forward gears when the selector lever is in the (D)
position; this engbraking will slow the vehicle and assist the driver in controlling the vehicle when descending
a grade. Depending on driving and load conditions, the transmission may downshift, slow the vehicle and
control the vehicle speed when descending a hill. To deactivate the tow/haul feature and return to normal
driving mode, press the tow/haul switch on the end of the selector lever or floor selector lever knob. The
words TOW HAUL will no longer be illuminated on the Instrument Cluster (IC). When the ignition switch is
cycled, the transmission will automatically return to normal (D) mode (Tow/Haul OFF). Do not use the
tow/haul feature when driving in icy conditions.
External Controls 2797

External Controls 2798


External Controls - Column Shift
Special Tool(s)

1. Verify the customer concern by operating the transmission external control.
2. Visually inspect for obvious signs of mechanical and electrical damage; refer to the following chart:
Damaged Brake Shift Interlock Actuator Failed fuse(s):
(BSIA) Smart Junction Box
Damaged tow/haul switch (SJB) 5 (10A)
Battery Junction Box
(BJB) 43 (15A)
Loose or corroded
connections
3. If the fault is not visually evident, determine the symptom. GO to Symptomrt - External Controls,
Column Shift or GO to Symptom Chart - NVH Column Shift .
DTC Chart

B2572 Brake Shift BSIA output The associated circuitry connected BSIA is GO to
Interlock circuit failure to the Smart Junction Box (SJB) inoperative or does Pinpoint
Actuator (BSIA) or fuse, or the SJB itself may have not operate Test A .
an issue causing a BSIA concern. correctly.
Symptom Chart - External Controls, Column Shift
Symptom Chart - External Controls, Column Shift
External Controls - Column Shift 2799

Symptom Chart - NVH Column Shift
Symptom Chart - NVH Column Shift

engine speed
Selector lever cable incorrectly routed, grounded out or loose
CHECK the selector lever cable. REPAIR as necessary. REFER to Selector Lever Cable and Bracket
- Column Shift in this section.
Rattle, buzz or other noise
Selector lever loose
TIGHTEN the selector lever bolts.
Selector lever knob
INSTALL a new selector lever knob. REFER to Selector Lever Knob in this section.
Selector lever
INSTALL a new selector lever. REFER to Selector Lever - Column Shift in this section.
Selector lever cable assembly grommet
SECURE the grommet to the floor panel.
Pinpoint Tests
NOTE: Refer to all TSBs and On-Line Automotive Service Informaon System (OASIS) messages that
pertain to the transmission concern and follow the procedure as described.
External Controls - Column Shift 2800

Pin Number Circuit Circuit Description

1 CET34 (BN/GN) Tow/haul signal
2 VDB05 (WH) HS CAN-
3 - NOT USED
4 - NOT USED
5 - NOT USED
6 VDB04 (WH/BU) HS CAN+
7 CAT03 (GY/BN) Backup lamp relay feed
8 - NOT USED
9 CBB54 (VT/OG) Ignition input
10 CET40 (GN/OG) Park/Neutral
11 - NOT USED
12 - NOT USED
13 GD113 (BK/YE) Ground
14 SBB26 (YE/RD) Battery input
15 RET24 (BN/BU) Backup lamp relay control
Brake Shift Interlock Actuator (BSIA) - C2008

1 Ground
2 Park detect
3 BSIA power
Tow/Haul Switch - C2399


1 Tow/haul switch ground
2 Tow/haul switch power
3 Not used
PINPOINT TEST A: THE BSIA SYSTEM DOES NOT RELEASE/LOCK CORRECTLY
NOTE: Perform a thorough inspection of the selector lever cable before proceeding with this pinpoint test.

A1 TEST THE BRAKE SWITCH
Yes
Apply the brake pedal and observe the High
Mounted Stoplamp. No
Does the High Mounted Stoplamp illuminate? REFER to Section 417-01 .
A2 TEST SJB FUSE 5 (10A)
Yes
Check fuse: Smart Junction Box (SJB) 5 (10A). GO to A4 .
No
GO to A3 .
A3 CHECK CIRCUIT CDC37 (GY/VT) FOR A
SHORT TO GROUND
Yes
Disconnect: Brake Shift Interlock Actuator GO to A4 .
(BSIA) C2008.
Disconnect: SJB C2280C. No
Inspect C2008, C2280C, C2239 and C214 for REPAIR circuit CDC37 (GY/VT) for a short
damaged or pushed-out terminals, corrosion or to ground. CLEAR DTCs. TEST the system
loose wires. Repair as necessary. for normal operation.
Measure the resistance between the BSIA
C2008-3, circuit CDC37 (GY/VT) harness side
and ground.
Tow/Haul Switch - C2399 2802


A4 CHECK CIRCUIT CDC37 (GY/VT) FOR AN
OPEN
Yes
Measure the resistance between the BSIA GO to A5 .
C2008-3, circuit CDC37 (GY/VT) and SJB
C2280C-23, circuit CDC37 (GY/VT), harness No
side. REPAIR circuit CDC37 (GY/VT) for an open.
CLEAR DTCs. TEST the system for normal
operation.

A5 TEST CIRCUIT GD138 (BK/WH) FOR AN
OPEN
Yes
Measure the resistance between the BSIA GO to A6 .
C2008-1, circuit GD138 (BK/WH), harness side
and ground. No
REPAIR circuit GD138 (BK/WH) for an open.
CLEAR DTCs. TEST the system for normal
operation.

A6 TEST CIRCUIT CDC37 (GY/VT) FOR
VOLTAGE
Yes
Connect: SJB C2280C. INSTALL a new BSIA . REFER to Brake
Measure the voltage between the BSIA Shift Interlock Actuator - Column Shift in this
C2008-3, circuit CDC37 (GY/VT), harness side section. CLEAR DTCs. TEST the system for
and ground, while applying the brake pedal. normal operation.
No
INSTALL a new SJB . REFER to Section
418-00 . CLEAR DTCs. TEST the system for
PINPOINT TEST A: THE BSIA SYSTEM DOES NOT RELEASE/LOCK CORRECTLY 2803
normal operation.
Is the voltage greater than 10 volts with the

brake pedal applied?
PINPOINT TEST B: THE SHIFT CONTROL IS OUT OF CORRECT GEAR RELATIONSHIP

B1 CHECK THE SHIFT CONTROL
LINKAGE
Yes
Apply the brake pedal. INSTALL a new column shift control linkage. TEST the
Gain access to the column shift system for normal operation.
control linkage.
Position the selector lever in all No
ranges. GO to B2 .
Observe all linkages during
operation.
Is the linkage damaged?
B2 CHECK THE SELECTOR
LEVER CABLE
Yes
Check selector lever cable and VERIFY the selector lever cable adjustment. REFER to
bracket for installation and Selector Lever Cable Adjustment in this section. ADJUST
tightness. the selector lever cable if necessary. GO to B3 .
Is the selector lever cable
correctly installed and adjusted? No
REPAIR as necessary. TEST the system for normal
operation.
B3 CHECK THE LINKAGE/CABLE
FOR CORRECT GEAR
RELATIONSHIP
Yes
Apply the brake pedal. System OK. TEST the system for normal operation.
Position the selector lever in all
ranges. No
Does the indicator match the REFER to Section 413-01 .
gear selection?
PINPOINT TEST C: THE TOW/HAUL SWITCH DOES NOT OPERATE CORRECTLY

C1 CHECK CIRCUIT CET34 (BN/GN) FOR VOLTAGE
PINPOINT TEST B: THE SHIFT CONTROL IS OUT OF CORRECT GEAR RELATIONSHIP 2804
Disconnect: Tow/Haul Switch C2399. Yes

Inspect C2399 for damaged or pushed-out terminals, GO to C3 .
corrosion or loose wires. Repair as necessary.
Ignition ON. No
Measure the voltage between the tow/haul switch, GO to C2 .
C2399-2, circuit CET34 (BN/GN), harness side and
ground.

C2 CHECK CIRCUIT CET34 (BN/GN) FOR AN OPEN
Yes
Disconnect: Transmission Vehicle Harness C1548. GO to C3 .
Inspect C1548 for damaged or pushed-out terminals,
corrosion or loose wires. Repair as necessary. No
Measure the resistance between the tow/haul switch, REPAIR circuit CET34 (BN/GN)
C2399-2, circuit CET34 (BN/GN) and the transmission for an open. TEST the system for
vehicle harness, C1548-1, circuit CET34 (BN/GN), normal operation.
harness side.

C3 CHECK CIRCUIT GD133 (BK) FOR AN OPEN
Yes
Measure the voltage between the tow/haul switch, INSTALL a new selector lever.
C2399-2 and C2399-1, harness side. REFER to Selector Lever - Column
Shift in this section. TEST the
No
REPAIR circuit GD133 (BK) for an
open. If no open is found,
REPLACE the Transmission Control
Module (TCM). TEST the system
PINPOINT TEST C: THE TOW/HAUL SWITCH DOES NOT OPERATE CORRECTLY 2805
PINPOINT TEST C: THE TOW/HAUL SWITCH DOES NOT OPERATE CORRECTLY 2806

External Controls - Floor Shift
Special Tool(s)

1. Verify the customer concern by operating the transmission external control.
2. Visually inspect for obvious signs of mechanical and electrical damage; refer to the following chart:
Damaged Brake Shift Interlock Actuator Failed fuse(s):
(BSIA) Smart Junction Box
Damaged tow/haul switch (SJB) 5 (10A)
Battery Junction Box
(BJB) 43 (15A)
Loose or corroded
connections
3. If the fault is not visually evident, determine the symptom. GO to Symptom t - External Controls,
Floor Shift or GO to Symptom Chart - NVH Floor Shift .
DTC Chart

B2572 Brake Shift BSIA output The associated circuitry connected BSIA is GO to
Interlock circuit failure to the Smart Junction Box (SJB) inoperative or does Pinpoint
Actuator (BSIA) or fuse, or the SJB itself may have not operate Test D .
an issue causing a BSIA concern. correctly.
Symptom Chart - External Controls, Floor Shift
Symptom Chart - External Controls, Floor Shift
External Controls - Floor Shift 2807

Symptom Chart - NVH Floor Shift
Symptom Chart - NVH Floor Shift

engine speed
Selector lever cable incorrectly routed, grounded out or loose
CHECK the selector lever cable. REPAIR as necessary. REFER to Selector Lever Cable and Bracket
- Floor Shift in this section.
Rattle, buzz or other noise
Selector lever loose
TIGHTEN the selector lever bolts.
Selector lever knob
INSTALLew selector lever knob. REFER to Selector Lever Knob in this section.
Selector lever
INSTALL a new selector lever. REFER to Selector Lever - Floor Shift in this section.
Cable assembly grommet
SECURE the grommet to the floor panel.
Pinpoint Tests
NOTE: Refer to all TSBs and On-Line Automotive Service Information System (OASIS) messages that
pertain to the transmission concern and follow the procedure as described.
External Controls - Floor Shift 2808

Pin Number Circuit Circuit Description

1 CET34 (BN/GN) Tow/haul signal
2 VDB05 (WH) HS CAN-
3 - NOT USED
4 - NOT USED
5 - NOT USED
6 VDB04 (WH/BU) HS CAN+
CAT03 (GY/BN) Backup lamp relay feed
8 - NOT USED
9 CBB54 (VT/OG) Ignition input
10 CET40 (GN/OG) Park/Neutral
11 - NOT USED
12 - NOT USED
14 SBB26 (YE/RD) Battery input
15 RET24 (BN/BU) Backup lamp relay control
Selector Lever Connector - C2096

1 BSIA power
2 Park detect
3 Illumination
4 Ground
5 Tow/haul switch power
6 Tow/haul switch ground

PINPOINT TEST D: THE BSIA DOES NOT RELEASE/LOCK CORRECTLY
NOTE: Perform a thorough inspection of the selector lever cable before proceeding with this pinpoint test.

D1 TEST THE BRAKE SWITCH
Yes
Ignition ON. GO to D2 .
Apply the brake pedal and observe the High
Mounted Stoplamp. No
Does the High Mounted Stoplamp illuminate? REFER to Section 417-01 .
D2 TEST SJB FUSE 5 (10A)
Yes
Check fuse: Smart Junction Box (SJB) 5 (10A). GO to D4 .
No
GO to D3 .
D3 CHECK CIRCUIT CDC37 (GY/VT) FOR A
SHORT TO GROUND
Yes
Disconnect: Selector Lever C2096. GO to D4 .
Disconnect: SJB C2280C.
Inspect C2096, C2280C and C314 for damaged or No
pushed-out terminals, corrosion or loose wires. REPAIR circuit CDC37 (GY/VT) for a short
Repair as necessary. to ground. CLEAR DTCs. TEST the system
Measure the resistance between selector lever for normal operation.
C2096-1, circuit CDC37 (GY/VT), harness side
and ground.

D4 CHECK CIRCUIT CDC37 (GY/VT) FOR AN
OPEN
Yes
Measure the resistance between selector lever GO to D5 .
C2096-1, circuit CDC37 (GY/VT), harness side
and SJB C2280C-23, circuit CDC37 (GY/VT), No
harness side. REPAIR circuit CDC37 (GY/VT) for an
open. CLEAR DTCs. TEST the system for
normal operation.
PINPOINT TEST D: THE BSIA DOES NOT RELEASE/LOCK CORRECTLY 2810


D5 TEST CIRCUIT GD143 (BK/VT) FOR AN OPEN
Yes
Measure the resistance between selector lever GO to D6 .
C2096-4, circuit GD143 (BK/VT), harness side
and ground. No
REPAIR circuit GD143 (BK/VT) for an
open. CLEAR DTCs. TEST the system for
normal operation.

D6 TEST CIRCUIT CDC37 (GY/VT) FOR
VOLTAGE
Yes
Connect: SJB C2280C. INSTALL a new selector lever. REFER to
Measure the voltage between the selector lever Brake Shift Interlock Actuator - Floor Shift
C2096-1, circuit CDC37 (GY/VT), harness side in this section. CLEAR DTCs. TEST the
and ground, while applying the brake pedal. system for normal operation.
No
INSTALL a new SJB . REFER to Section
418-00 . CLEAR DTCs. TEST the system
Is the voltage greater than 10 volts with the

brake pedal applied?
PINPOINT TEST E: THE SHIFT CONTROL IS OUT OF CORRECT GEAR RELATIONSHIP

E1 CHECK THE SHIFT CONTROL
LINKAGE
Apply the brake pedal.

Gain access to the shift control
linkage.
PINPOINT TEST E: THE SHIFT CONTROL IS OUT OF CORRECT GEAR RELATIONSHIP 2811

ranges.
Observe all selector lever
linkages during operation.
Is the selector lever linkage
damaged?
E2 CHECK THE SELECTOR
LEVER CABLE
Yes
Check the selector lever cable VERIFY the selector lever cable adjustment. REFER to
and bracket installation and Selector Lever Cable Adjustment in this section. ADJUST the
tightness. selector lever cable if necessary. If selector lever cable
Is the selector lever cable adjustment is correct, INSTALL a new main control valve
correctly installed and body. REFER to Section 307-01 . GO to E3 .
adjusted?
No
REPAIR as necessary. TEST the system for normal operation.
E3 CHECK THE LINKAGE/CABLE
FOR CORRECT GEAR
RELATIONSHIP
Yes
Apply the brake pedal. System OK. TEST the system for normal operation.
ranges. No
Does the indicator match the REFER to Selector Lever Cable Adjustment in this section.
gear selection? TEST the system for normal operation.
PINPOINT TEST F: THE TOW/HAUL SWITCH DOES NOT OPERATE CORRECTLY

F1 CHECK CIRCUIT CET 34 (BN/GN) FOR
VOLTAGE
Yes
Disconnect: Selector Lever C2096. GO to F3 .
Inspect C2096 for damaged or pushed-out
terminals, corrosion or loose wires. Repair as No
necessary. GO to F2 .
Ignition ON.
Measure the voltage between the selector lever
C2096-5, circuit CET 34 (BN/GN) harness side
and ground.
PINPOINT TEST F: THE TOW/HAUL SWITCH DOES NOT OPERATE CORRECTLY 2812
F2 CHECK CIRCUIT CET 34 (BN/GN) FOR AN

OPEN
Yes
Disconnect: Transmission Vehicle Harness C1548. GO to F3 .
Inspect C1548 for damaged or pushed-out
terminals, corrosion or loose wires. Repair as No
necessary. REPAIR circuit CET34 (BN/GN) for an
Measure the resistance between the selector lever open. TEST the system for normal
C2096-5, circuit CET34 (BN/GN) and the operation.
transmission vehicle harness C1548-1, circuit
CET34 (BN/GN), harness side.

F3 CHECK CIRCUIT GD133 (BK) FOR AN OPEN
Yes
Measure the voltage between the selector lever INSTALL a new selector lever knob.
C2096-6 and C2096-5, harness side. REFER to Selector Lever Knob in this
operation.
No
REPAIR circuit GD133 (BK) for an open. If
no open is found, REPLACE the
Transmission Control Module (TCM).

Brake Shift Interlock Override - Column Shift
NOTE: If it is necessary to use the brake shift interlock override procedure to move the selector lever from
the PARK position, it is possible that a fuse has blown and the brake lights are not operational. Before driving
the vehicle, verify that the brake lights are working.
This vehicle is equipped with a brake shift interlock system that prevents moving the selector lever from the
PARK position. When the ignition switch is in the RUN position and the brake pedal is applied, the Brake
Shift Interlock Actuator (BSIA) is energized.
Perform the following if the selector lever cannot be moved from PARK with the ignition switch in RUN and
the brake pedal applied:
1. Apply the park brake.
2. Turn the ignition switch to the RUN position.
3. Remove the access panel.
4. Using a suitable tool, move the BSIA spindle outward, apply the brake pedal and move the selector
lever into NEUTRAL.
5. Start tehicle.
6. To install, reverse the procedure.
Brake Shift Interlock Override - Column Shift 2815

Brake Shift Interlock Override - Column Shift 2816


Brake Shift Interlock Override - Floor Shift
NOTE: If it is necessary to use the brake shift interlock override procedure to move the selector lever from
the PARK position, it is possible that a fuse has blown and the brake lights are not operational. Before driving
the vehicle, verify that the brake lights are working.
This vehicle is equipped with a brake shift interlock system that prevents moving the selector lever from the
PARK position. When the ignition switch is in the RUN position and the brake pedal is applied, the Brake
Shift Interlock Actuator (BSIA) is energized.
Perform the following if the selector lever cannot be moved from PARK with the ignition switch in RUN and
the brake pedal applied:
All vehicles
1. Turn the ignition switch to the OFF position.
Expedition
3. Remove the selector lever trim ring, console tray and cup holder insert.
4. Remove the screw and the console upper trim.
Navigator
Brake Shift Interlock Override - Floor Shift 2817

6. NOTE: Using a suitable tool, lift and remove the floor console upper panel from the rear.
Remove the floor console upper panel.
All vehicles
7. Using a suitable tool, press the brake shift interlock override mechanism on the selector lever, apply
the brake pedal, press the button on the selector lever and move the selector lever into NEUTRAL.
1. Press the override mechanism forward to release the BSIA .
8. Start the vehicle.
9. To install, reverse the procedure.



Selector Lever Cable Adjustment
1. With the vehicle in NEUTRAL, position the vehicle on a hoist. For additional information, refer to
Section 100-02 .
2. Place the selector lever in the DRIVE position.
Disconnect the selector lever cable from the manual control lever.
5. NOTE: Make sure the cable moves freely.
Unlock the lock tab on the selector lever cable.
6. Place the manual control lever in the DRIVE position.

Place the manual control lever in the 1st gear position.
Move the manual control lever 3 detents to the DRIVE position.
Selector Lever Cable Adjustment 2820

securely installed onto the manual control lever. Pull back on the selector lever cable to make sure
that the selector cable end is securely installed onto the manual control lever.

installed.
9. NOTE: Install a new heat shield if it is loose on the cable.
If equipped, install the heat shield.
10. Carefully move the manual control lever from detent to detent and compare with transmission
settings. Verify that the vehicle will start in PARK or NEUTRAL and backup lamps illuminate in
REVERSE. If not, Steps 1 through 9 must be repeated.
Readjust if necessary.



Brake Shift Interlock Actuator - Column Shift

1 W710485-S Lower steering column shroud screws
2 3533-B Lower steering column shroud
3 3530-B Upper steering column shroud
4 - Brake Shift Interlock Actuator (BSIA)
electrical connector
5 3F907-A BSIA screw
6 3F770 BSIA
2. NOTICE: To prevent damage to the selector lever boot, do not pull out on the top of the boot
frame.
Remove the selector lever boot from the steering column shroud by pressing in on the selector lever
boot frame.
Brake Shift Interlock Actuator - Column Shift 2823

3. Position the selector lever boot up the selector lever.
4. NOTE: Steering wheel removed for clarity.
Unsnap and remove the upper steering column shroud from the lower shroud.
5. Pull back on the brake shift interlock plunger, apply the brake pedal and shift the transmission into
NEUTRAL.
6. Disconnect the Brake Shift Interlock Actuator (BSIA) electrical connector.
7. Remove the BSIA screw.
8. Gently pry the clip up and remove the BSIA .
9. NOTE: When installing the BSIA , verify that the BSIA override has been activated and the slider is
fully rearward. Before rotating the selector lever from NEUTRAL into PARK, align the selector lever

tab into the BSIA .


Brake Shift Interlock Actuator - Floor Shift
NOTE: The Brake Shift Interlock Actuator (BSIA) is not serviced individually. If installation of a new BSIA
is required, install a new floor shift selector lever assembly.
1. For additional information, refer to Selector Lever - Floor Shift in this section.
Brake Shift Interlock Actuator - Floor Shift 2826


Selector Lever Cable and Bracket - Column Shift

1 7J383 Heat shield (part of 7E395)
2 7E395 Selector lever cable
3 7H181-A Selector lever cable clip
4 N605905 Selector lever cable bracket bolts
5 7B229-A Selector lever cable bracket
6 - Rubber grommet (part of 7E395)
7 W710485-S Steering column lower shroud screws
8 3533-B Steering column lower shroud
9 - Selector lever cable eyelet (part of 7E395)
10 - Selector lever cable clip (part of 7E395)
11 - Selector lever cable retainer (part of 7E395)
Removal
100-02 .
2. Remove the instrument panel lower finish panel.
Selector Lever Cable and Bracket - Column Shift 2827

3. Remove the hood release cable lever.
4. Remove the instrument panel lower reinforcement panel.

1. Remove the screws and the lower shroud.
assembly between the steering column selector lever arm and the steering column bracket.
Disconnect the selector lever cable from the steering column.
1. Disconnect the selector lever cable from the selector lever arm.

2. Carefully lift the locking tab and disconnect the selector lever cable from the steering column
bracket.
3. Disconnect the selector lever cable retainer.
8. Push the rubber grommet and selector lever cable down through the dash panel.
Move the locking tab up and disconnect the selector lever cable from the manual control lever.
11. Remove the selector lever cable clip to release the selector lever cable from the selector lever cable
bracket.
12. Remove the bolts and the selector lever cable bracket from the transmission.

Installation
1. Install the selector lever cable bracket and bolts onto the transmission.
NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs
are locked in place. Press the selector lever cable into the selector lever cable bracket and listen for
the selector lever cable to click into place. Pull back on the selector lever cable to make sure that the
selector lever is locked into the selector lever cable bracket.
Install the selector lever cable into the selector lever cable bracket.
correctly installed onto the manual control lever. Pull back on the selector lever cable to make sure

installed.

6. Push the selector lever cable and rubber grommet up through the dash panel.
7. NOTICE: To prevent cable damage, do not apply force to the selector lever cable assembly
between the steering column selector lever arm and the steering column bracket.
Connect the selector lever cable onto the steering column.
1. Connect the selector lever cable retainer.

2. Connect the selector lever cable onto the steering column bracket.
Pull back on the selector lever cable to make sure that it is securely installed.
5. Connect the selector lever cable onto the selector lever arm.

8. Install the steering column upper and lower shrouds.

1. Install the screws and the lower shroud.
9. Install the instrument panel lower reinforcement panel.

Tighten the screws to 9 Nm (80 lb-in).
10. Install the hood release cable lever.

Tighten the bolts to 9 Nm (80 lb-in).
11. Install the instrument panel lower finish panel.
12. Adjust the selector lever cable. For additional information, refer to Selector Lever Cable Adjustment
in this section.



Selector Lever Cable and Bracket - Floor Shift

1 7J383 Heat shield (part of 7E395)
3 N605905 Selector lever cable bracket bolts
4 7B229 Selector lever cable bracket
5 - Rubber grommet (part of 7E395)
6 - Selector lever cable eyelet (part of 7E395)
7 - Selector lever cable clip (part of 7E395)
Removal
All vehicles
100-02 .
Expedition
Selector Lever Cable and Bracket - Floor Shift 2834

4. NOTE: The selector lever bezel has been removed from art for clarity. Do not remove the selector
lever bezel.
Disconnect the selector lever cable from the selector lever.
2. Disconnect the selector lever cable from the selector lever housing.
Navigator
lever bezel.
Disconnect the selector lever cable from the selector lever arm.

8. Remove the center console LH finish panel.
All vehicles
10. Remove the selector lever cable and rubber grommet.
Move the locking tab up and disconnect the selector lever cable from the manual control lever.

13. Remove the selector lever cable clip to release the selector lever cable from the selector lever cable
bracket.
14. Remove the bolts and the selector lever cable bracket from the transmission.
Installation
All vehicles
1. Install the selector lever cable bracket and bolts onto the transmission.
NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs
are locked in place. Press the selector lever cable into the selector lever cable bracket and listen for
the selector lever cable to click into place. Pull back on the selector lever cable to make sure that the
selector lever is locked into the selector lever cable bracket.
Install the selector lever cable into the selector lever cable bracket.

securely installed onto the manual control lever. Pull back on the selector lever cable to make sure
Connect the selector lever cable onto the manual control lever.

6. Install the selector lever cable and rubber grommet.

Expedition
7. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs
are locked in place. Press the selector lever cable into the bracket and listen for the selector lever
cable to click into place. Pull back on the selector lever cable to make sure that it is locked into the
bracket.
NOTE: The selector lever bezel has been removed from art for clarity. Do not remove the selector
lever bezel.
Connect the selector lever cable onto the selector lever.
1. Connect the selector lever cable onto the selector lever housing.
8. Install the console upper trim and the screw.
9. Install the selector lever trim ring, console tray and cup holder insert.
Navigator
bracket.
Connect the selector lever cable onto the selector lever housing.

11. Install the center console LH finish panel.
securely installed onto the selector lever ball stud. Pull back on the selector lever cable to make sure
that the selector cable end is securely installed onto the selector lever ball stud.
lever bezel.
Connect the selector lever cable onto the selector lever arm.

13. Install the floor console upper panel.

All vehicles
in this section.


Selector Lever - Column Shift

4 W712000-S Selector lever bolt
5 7202 Selector lever
6 3513 Selector lever boot
2. NOTICE: To prevent damage to the selector lever boot, do not pull on the top of the boot frame.
boot frame.
Selector Lever - Column Shift 2842

5. Remove the lower steering column shroud.

1. Remove the screws and the lower steering column shroud.
6. Disconnect the electrical connector and remove the screw that retains the harness clip to the steering
column.
7. Remove the selector lever bolt.

8. Remove the selector lever.



Selector Lever Mechanism
Selector Lever Mechanism

3 78045C90-A Instrument Cluster (IC) shroud trim
4 - IC trim screws
5 78044D70-A IC trim
6 - IC screw (4 required)
7 10849-A IC
9 W712000-S Selector lever bolt
10 7202-A Selector lever
11 7J248-A Selector lever mechanism bolt (3 required)
12 3C529-D Selector lever mechanism
13 3F907-A Brake Shift Interlock Actuator (BSIA) screw
14 3F770-A BSIA
Removal
1. Remove the instrument panel lower finish panel.
2. NOTICE: To prevent damage to the selector lever boot, do not pull on the top of the boot frame.
boot frame.
Selector Lever Mechanism 2845


1. Remove the screws and the lower shroud.
6. Remove the Instrument Cluster (IC) shroud trim.
7. Remove the RH IC trim screw.

8. Remove the LH IC trim screw and pull the IC trim from the instrument panel.
9. If equipped, disconnect the in-vehicle temperature sensor connector.
10. Disconnect the dimmer switch electrical connector and remove the IC trim.
11. Remove the upper IC screws.
12. Remove the RH lower IC screw.

13. Remove the LH lower IC screw and position the IC aside.
Disconnect the selector lever cable.
15. Remove the locking pin and the park lock cable.
1. Remove and discard the locking pin.
2. Disconnect the park lock cable.
16. Disconnect the electrical connector and remove the screw that retains the harness clip to the steering
column.
17. Remove the selector lever bolt.
18. Remove the selector lever.

19. Remove the selector lever mechanism lower bolt.
20. Disconnect the Brake Shift Interlock Actuator (BSIA) electrical connector and remove the selector
lever mechanism upper bolts and the selector lever mechanism from the vehicle.
21. Remove the BSIA from the selector lever mechanism.

1. Pull the BSIA override button.
2. Remove the BSIA screw.
3. Gently pry the clip up and remove the BSIA .
Installation
1. Install the BSIA onto the selector lever mechanism.

1. Pull the BSIA override button.
2. Align the selector lever tab into the BSIA .
3. Position and secure the BSIA with the clip.
4. Install the screw.

2. Install the selector lever mechanism into the vehicle, install the upper bolts and connect the BSIA
3. Install the selector lever mechanism lower bolt.

4. Install the selector lever.

5. Install the screw that retains the harness clip to the steering column and connect the electrical
connector.
6. Install the locking pin and the park lock cable.

1. Connect the park lock cable.
2. Install a new locking pin.

Connect the selector lever cable.
8. Position the IC and install the LH lower IC screw.
9. Install the RH lower IC screw.
10. Install the upper IC screws.
11. Position the IC trim and connect the dimmer switch electrical connector.
12. If equipped, connect the in-vehicle temperature sensor connector.

13. Install the LH IC trim screw.
14. Install the RH IC trim screw.
15. Install the IC shroud trim.
16. Install the steering column upper and lower shroud.

1. Install the lower shroud and the screws, then snap the upper shroud to the lower shroud.
17. Install the instrument panel lower finish panel.



Selector Lever - Floor Shift
Expedition

2 78045G34-B Console tray
3 78046B94-B Console cup holder insert
4 - Console upper trim panel screw
5 78045A76 Console upper trim panel
6 7210 Selector lever assembly
8 N606678-S Selector lever bolts
Navigator
Selector Lever - Floor Shift 2854


3
4 7D443 Selector lever bezel
6 N606678-S Selector lever bolts
7 7210 Selector lever assembly
8 - Center console finish panel
Removal
Expedition
Navigator 2855
lever bezel.
Disconnect the selector lever cable from the selector lever.
4. Disconnect the selector lever electrical connector.
lever bezel.
Remove the bolts and lift the selector lever out of the console.
Navigator
Navigator 2856
lever bezel.
Disconnect the selector lever cable from the selector lever arm ball stud.
9. Remove the center console LH finish panel.
11. Disconnect the selector lever electrical connector.
lever bezel.
Remove the bolts and lift the selector lever out of the console.
Navigator 2857
Installation
Expedition
lever bezel.
Install the selector lever into the console.
2. Connect the selector lever electrical connector.
bracket.
lever bezel.
Connect the selector lever cable onto the selector lever.
1. Connect the selector lever cable onto the selector lever housing.
Navigator 2858
Navigator
lever bezel.
Install the selector lever into the console.
7. Connect the selector lever electrical connector.
Navigator 2859
bracket.
Connect the selector lever cable onto the selector lever housing.
9. Install the center console LH finish panel.
bracket.
lever bezel.
Connect the selector lever cable onto the selector lever arm.

Navigator 2860
All vehicles
in this section.
Navigator 2861

Selector Lever Knob
Expedition

5 78045A76-A Console upper trim panel
6 7L468 Selector lever knob covers
7 W790088 Selector lever knob screws
8 - Selector lever shroud (part of 7213)
9 7213 Selector lever knob
Navigator
Selector Lever Knob 2862


3 78044J76-A Console upper trim panel
Removal
1. NOTE: Expedition selector lever shown, Navilar.
Remove the selector lever trim ring, console tray and cup holder insert.
Navigator 2863
3. Remove and discard the RH selector lever knob cover.
1. Start at the bottom front only.
2. Move towards the top front and remove the cover.
4. Remove and discard the LH selector lever knob cover.

5. Remove and discard the RH selector lever knob screw.
6. NOTE: Verify the LH and RH knob body towers are present and not damaged.
Remove and discard the LH selector lever knob screw.
7. Disconnect the tow/haul switch electrical connector and remove the selector lever knob.
Installation
Navigator 2864
1. Connect the tow/haul switch electrical connector and install the selector lever knob.
2. Install a new LH selector lever knob screw.

3. Install a new RH selector lever knob screw.

4. Install a new LH selector lever knob cover.
5. Install a new RH selector lever knob cover.
Navigator 2865
Navigator 2866

Selector Lever Bezel
Expedition

5 78045A76-A Console upper trim panel
11 7A214 Selector lever bezel override cap
Navigator
Selector Lever Bezel 2867


3 78044J76-A Console upper trim panel
9 7A214 Selector lever bezel override cap
Removal
Expedition
Navigator 2868
Navigator
All vehicles
5. Remove and discard the RH selector lever knob cover.

6. Remove and discard the LH selector lever knob cover.

7. Remove and discard the RH selector lever knob screw.
Navigator 2869
8. NOTE: Verify the LH and RH knob body towers are present and not damaged.
Remove and discard the LH selector lever knob screw.
9. Disconnect the tow/haul switch electrical connector and remove the selector lever knob.
10. Lift the tabs on the selector lever bezel and lift the bezel for access to the electrical harness.
Expedition
11. Disconnect the electrical harness from the bezel.
Installation
Expedition
1. Connect the electrical harness onto the bezel.
Navigator 2870
All vehicles
2. Install the selector lever bezel onto the selector lever housing.
3. Connect the tow/haul switch electrical connector and install the selector lever knob.
4. Install a new LH selector lever knob screw.

5. Install a new RH selector lever knob screw.

6. Install a new LH selector lever knob cover.
Navigator 2871
7. Install a new RH selector lever knob cover.
Expedition
Navigator
Navigator 2872
Navigator 2873

Transmission Control (TC) Switch - Column Shift
NOTE: The tow/haul switch is not replaceable. If a new tow/haul switch is required, install a new selector
lever assembly.
1. For additional information, refer to Selector Lever - Column Shift in this section.
Transmission Control (TC) Switch - Column Shift 2874


Transmission Control (TC) Switch - Floor Shift
NOTE: The tow/haul switch is not serviced. If a new switch is required, install a new selector lever knob
assembly.
1. For additional information, refer to Selector Lever Knob in this section.
Transmission Control (TC) Switch - Floor Shift 2875

SECTION 308-07A: Four Wheel Drive (4WD) Systems 2011 Expedition, Navigator Workshop Manual
Material

TA-30

Axle nut 40 30 -
Front brake flexible hose bracket bolt 12 - 106
Tie-rod nut 115 85 -
Transfer case shift motor bolts 10 - 89
Transfer case shift motor bracket bolt 10 - 89
Transfer case shift motor bracket nuts 3 - 27
Wheel speed sensor harness bracket bolt - 106
Transmission Control (TC) Switch - Floor Shift 2876


SECTION 308-07A: Four Wheel Drive (4WD) Systems
Manual
Four Wheel Drive (4WD) Systems
The 1-speed torque-on-demand (Navigator) and 2-speed torque-on-demand (Expedition) Four-Wheel Drive
(4WD) systems consist of the following:
Mode Select Switch (MSS)

4X4 control module
Integrated Wheel End (IWE) solenoid
IWEs
4WD mode indicators and messages in the Instrument Cluster (IC) message center
Transfer case assembly
Transfer case shift motor
Steering wheel angle signal from ABS module via High Speed Controller Area Network (HS-CAN)
Accelerator Pedal Position (APP) output from the PCM via HS-CAN
Wheel speed signals from the ABS via HS-CAN
Integrated Wheel End (IWE) System
The IWE system consists of the following:
Vacuum reservoir
IWE solenoid
IWEs (spring-loaded vacuum hubs)
Vacuum hoses
Check valve
The IWE system uses vacuum hubs that engage the front wheel hubs to the front halfshafts or disengage the
front wheel hubs from the front halfshafts.
The IWE solenoid receives engine vacuum from the vacuum reservoir.
When the 4WD system is in 2-Wheel Drive (2WD) mode, the 4X4 control module supplies a ground path to
the IWE solenoid to apply vacuum to the IWEs (disengaging the front hubs from the front halfshafts). In 4WD
mode, the 4X4 control module does not supply the ground path to the IWE solenoid, vacuum is not applied to
the IWEs and an internal spring keeps the front hubs engaged to the front halfshafts.
Four Wheel Drive (4WD) Systems 2877

Four Wheel Drive (4WD) Systems 2878

Four Wheel Drive (4WD) Systems - 1-Speed Torque-On-Demand
Special Tool(s)
Flex Probe Kit



The Navigator is equipped with an automatic, electronic-shift system that allows the operator to choose (by
pressing the mode select buttons) between 3 different modes: 4X2, 4X4 AUTO and 4X4. The operator can
switch between any mode at any speed.
Wheel slip is sensed by monitoring the average front and rear wheel speeds. Based on steering w angle,
Accelerator Pedal Position (APP) and wheel slip, a Pulse-Width Modulation (PWM) signal is transmitted to
the transfer case as torque is required. The Transfer Case Control Module (TCCM) will provide the ABS with
current clutch duty cycle and whether or not ABS may command the clutch duty cycle.
The brake subsystem sends the following information signals to the Four-Wheel Drive (4WD) system over the
High Speed Controller Area Network (HS-CAN):
Occurrences of brake events and failures. Refer to Section 206-09 .

Steering wheel angle status. Refer to Section 206-09 .
Wheel speeds. Refer to Section 206-09 .
A concern with any of the above listed brake system signals or the HS-CAN will affect operation of the 4WD
system.
The APP output signal is provided to the TCCM from the PCM. This signal is used by the TCCM in
controlling the transfer case clutch.
The TCCM sends a duty cycle command to the clutch coil which activates the clutch within the transfer case.
The TCCM varies the torque sent to the front driveline by controlling the transfer case clutch. At rest and
under cruising conditions, the TCCM activates the transfer case clutch at minimum duty cycle (percentage of
time the clutch is turned on), which allows for the slight difference between the front and rear driveshafts
which normally occurs when negotiating a corner on dry pavement. Under any of the following conditions,
the TCCM will increase the duty cycle in order to prevent or control slip:
Slip is detected
Four Wheel Drive (4WD) Systems - 1-Speed Torque-On-Demand 2879

Heavy acceleration (throttle position)

Straight-ahead steering wheel angle
Feature inputs:

APP (from the PCM)
Steering wheel angle (from the ABS module)
Transmission Range (TR) position (from the PCM)
Transmission output torque (from the PCM)
Wheel speed signal (transmitted from the ABS module)
Feature outputs:
Solid state PWM signal

Message center 4WD mode indicators
Halfshafts Battery Junction Box (BJB)

Integrated Wheel fuses:
End (IWE) 27 (20A)
Driveshaft and 29 (20A)
U-joints Smart Junction Box (SJB) fuse 35
Vacuum leaks (10A)
Fluid leaks Transfer Case Control Module
Matching tire sizes (TCCM)
Transfer case Mode Select Switch (MSS)
IWE solenoid
Wiring harness
Connector(s)
Circuitry



verify the ignition is in the ON position.

418-00 .
(CMDTCs).
8. Clear the DTCs and carry out the self-test diagnostics for the TCCM .
9. NOTE: Before carrying out the on-demand self test, make sure that:
the ignition is in RUN.

2-Wheel Drive (2WD) mode is selected.
If the DTCs retrieved are related to the concern, go to the Transfer Case Control Module (TCCM)
DTC Chart. For all other DTCs, refer to Section 419-10 .
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart - Four Wheel Drive (4WD) or
GO to Symptom Chart - NVH .
DTC Charts
Transfer Case Control Module (TCCM) DTC Chart

C1979:11 IWE Solenoid Circuit Failure: Circuit Short GO to Pinpoint Test C .
To Ground
C1979:12 IWE Solenoid Circuit Failure: Circuit Short GO to Pinpoint Test C .
To Battery
C1979:13 IWE Solenoid Circuit Failure: Circuit Open GO to Pinpoint Test C .
P0562:00 Battery Voltage Low: No Sub Type GO to Pinpoint Test B .
Information
P0563:00 Battery Voltage High: No Sub Type GO to Pinpoint Test B .
Information
P1812:00 4-Wheel Drive Mode Select Circuit Failure: GO to Pinpoint Test D .
No Sub Type Information

P1815:00 4-Wheel Drive Mode Select Short Circuit to GO to Pinpoint Test D .

Ground: No Sub Type Information
P1825:00 4-Wheel Drive Clutch Relay Open Circuit: GO to Pinpoint Test E .
P1826:00 4-Wheel Drive Low Clutch Relay Circuit To GO to Pinpoint Test E .
Battery: No Sub Type Information
P1827:00 4-Wheel Drive Low Clutch Relay Circuit To GO to Pinpoint Test E .
P1886:00 4X4 Initialization Failure: No Sub Type CLEAR the DTC. REPEAT the self-test. If
Information the DTC still reports, CONFIRM the Transfer
Case Control Module (TCCM) part number is
correct for the vehicle.
U0100:00 Lost Communication with ECM/PCM "A": REFER to Section 418-00 to diagnose the lost
No Sub Type Information communication with the PCM.
U0121:00 Lost Communication with Anti-Lock Brake REFER to Section 418-00 to diagnose the lost
System (ABS) Control Module: No Sub communication with the ABS module.
Type Information
U0418:00 Invalid Data Received From Brake System REFER to Section 206-09 to diagnose the
Control Module: No Sub Type Information wheel speed sensor concern.
U3000:04 Control Module: System Internal Failure CLEAR the DTC. REPEAT the self-test. If
DTC U3000:04 is retrieved, INSTALL a new
TCCM . REFER to 4X4 Control Module in
this section. REPEAT the self-test.
U3000:41 Control Module: General Checksum Failure CLEAR the DTC. REPEAT the self-test. If
U3000:49 Control Module: Internal Electronic Failure CLEAR the DTC. REPEAT the self-test. If
U300D:11 Ignition Input On/Start: Short Circuit To GO to Pinpoint Test A .
Ground
Symptom Chart - Four-Wheel Drive (4WD)
Symptom Chart - NVH
Symptom Chart - NVH


Grinding noise during 4WD system engagement, especially at high speeds
Front halfshaft speeds not turning at the same speed

Sychronization clutch
Straightline driveline wind-up
Unmatched tire sizes

Unequal amounts of tire wear
Unequal tire inflation pressures
Unmatched front and rear axle ratios
GO to Pinpoint Test G .
The front axle makes noise in 2H mode only and generally under heavy throttle
Vacuum leaks
Vacuum lines
Vacuum check valves
Vacuum reservoir
IWE solenoid
IWE
The transfer case makes noise
Tire inflation pressure

Tire and wheel size
MAKE SURE that all tires and wheels are the same size and that the inflation pressures are correct.
Tire tread wear
CHECK tire tread wear to see if there is more than 0.15 mm (0.06 in) difference in tread wear
between front and rear. INTERCHANGE one front wheel and one rear wheel. ROAD TEST again.
Internal components
OPERATE the vehicle in all transmission gears. If there is noise in the transmission in NEUTRAL, or
in some gears and not in others, REMOVE and REPAIR the transmission. REFER to Section 307-01 .
If there is noise in all gears, DISASSEMBLE the transfer case. REFER to Section 308-07B . CHECK
the planetary gears, the bearings, the upper and lower drive sprockets and drive chain for damage.
INSTALL new parts as necessary.
Fluid level
FILL to the correct level and with the specified fluid. REFER to Section 308-07B .
The vehicle binds in turns/resists turning/pulsates/shudders in a straight line

GO to Pinpoint Test K .
Transfer case whine - noise at all ranges
Incorrect fluid level or fluid quality

Worn oil pump
Under-inflated or oversized tires
CHECK that the transfer case is filled to the correct level and with the specified fluid. REFER to
Section 308-07B .
DISASSEMBLE the transfer case. CHECK the oil pump for wear or damage. REPAIR as necessary.
REFER to Section 308-07B .
CONFIRM that the tires and wheels are correct for the vehicle. CHECK that the tire inflation
pressures are correct.
Transfer case growl/rumble - noise at all ranges
Damaged or worn bearings or planetary gear
DISASSEMBLE the transfer case. CHECK the bearings or planetary gear for wear or damage.
REPAIR as necessary. REFER to Section 308-07B .
Transfer case scraping/grating - noise at all ranges
Excessively stretched drive chain hitting the case
DISASSEMBLE the transfer case. CHECK the drive chain for wear or damage. REPAIR as
necessary. REFER to Section 308-07B .
Transfer case howl/hum - noise at all ranges or 4X4 only
Worn or damaged sun (input) gear, clutch pack (intermediate) gear or output shaft gear
DISASSEhe transfer case. CHECK the gears for wear or damage. REPAIR as necessary. REFER to
Section 308-07B .
Pinpoint Tests
Pinpoint Test A: DTC U300D:11
Refer to Wiring Diagrams Cell 34 , Four-Wheel Drive System for schematic and connector information.
Normal Operation
The Transfer Case Control Module (TCCM) receives ignition switch position status from the hardwired
run/start input to TCCM pin 7 and the ignition switch position status message communicated by the
Instrument Cluster (IC) over the High Speed Controller Area Network (HS-CAN). The ignition switch

position status message originates from the Smart Junction Box (SJB) which communicates the ignition
switch position status over the Medium Speed Controller Area Network (MS-CAN) to the IC which acts as a
gateway module, transferring the ignition switch status message from MS-CAN to HS-CAN . For information
regarding network messaging, refer to Section 418-00 .
DTC U300D:11 (Ignition Input On/Start: Circuit Short To Ground) - Fault sets when TCCM detects a
short to ground on C2371A-7. If the ignition switch is not in RUN for the self-test, this code will set.

Fuse
Ignition switch and/or circuitry
HS-CAN
PINPOINT TEST A: DTC U300D:11

A1 CHECK THE TCCM
IGNITION POSITION
(KEY_POS_4X4) AND IGNITION
STATUS (KEY_STATUS_4X4)
PIDs
Yes
Enter the following diagnostic The system is functioning correctly. CLEAR the DTCs. REPEAT
mode on the scan tool: the self-test.
DataLogger - TCCM .
Monitor the ignition position No
KEY_POS_4X4 and If the KEY_STATUS_4X4 PID did not match, CHECK Smart
KEY_STATUS_4X4 PIDs Junction Box (SJB) fuse 35 (10A). If the fuse is OK, REPAIR
while cycling through each circuit CBP35 (YE/GY). If the fuse is not OK, REFER to the
position. Wiring Diagrams manual to identify the possible causes of the
Do the ignition PIDs match circuit short. After the fault is repaired, CLEAR the DTCs. TEST
the ignition switch the system for normal operation.
positions?
If the KEY_POS_4X4 PID did not match, REFER to Section
211-05 to diagnose the ignition switch. After the fault is repaired,
CLEAR the DTCs. TEST the system for normal operation.
Pinpoint Test B: DTC P0562:00 or P0563:00
Normal Operation
If the Transfer Case Control Module (TCCM) observes an overpower or underpower voltage condition, a
DTC Is set and all TCCM outputs are turned off (Integrated Wheel Ends (IWEs) engaged).
DTC P0562:00 (System Voltage Low: No Sub Type Information) - Fault sets when the TCCM detects
less than 9 volts of battery voltage for 5 seconds or more at TCCM C2371B pin 7.
DTC P0563:00 (System Voltage High: No Sub Type Information) - Fault sets when the TCCM
detects more than 16 volts of battery voltage for 5 seconds or more at TCCM C2371B pin 7.
PINPOINT TEST A: DTC U300D:11 2885

Fuse
TCCM
PINPOINT TEST B: DTC P0562:00 OR P0563:00
NOTE: DTC P0562:00 or P0563:00 can be set if the vehicle has been recently jump started, the battery has
been rtly charged or the battery has been discharged. The battery may become discharged due to excessive
load(s) on the charging system from aftermarket accessories or if the battery has been left unattended with the
accessories on.
NOTE: Carry out a thorough inspection and verification before proceeding with the pinpoint test. Refer to
Inspection and Verification in this section.

B1 RETRIEVE ALL CMDTCs IN ALL MODULES
Yes
Ignition ON. REFER to Section 414-00 for diagnosis
Enter the following diagnostic mode on the scan tool: of the battery and charging system.
Self-Test - All CMDTCs .
Is P0562:00 or P0563:00 present in one or more No
modules AND P0563, P0620, P0625, P0626 or GO to B2 .
P065B present in the PCM?
B2 CHECK BATTERY CONDITION
Yes
Refer to Section 414-01 and carry out the Battery -
Condition Test. No
Does the battery pass the condition test? CHARGE or INSTALL a new battery as
necessary. REFER to Section 414-01 .
CLEAR all CMDTCs . TEST the system
B3 CHECK THE CHARGING SYSTEM VOLTAGE
Yes
NOTE: Do not allow the engine rpm to increase above For DTC P0562:00, GO to B4 .
2,000 rpm while performing this step or the generator
may self excite and result in defat charging system For DTC P0563:00, GO to B6 .
output voltage. If engine rpm has gone above 2,000
rpm, shut the vehicle OFF and restart the engine No
before performing this step. REFER to Section 414-00 to diagnose
the charging system. CLEAR all
Start the engine. CMDTCs . TEST the system for normal
Measure the voltage of the battery: operation.
For DTC P0562:00, turn on headlights and
HVAC fan on high and run engine at 1,500
rpm for a minimum of 2 minutes.
For DTC P0563:00, turn off all accessories
and run the engine at 1,500 rpm for a
minimum of 2 minutes.

Is the battery voltage between 13-15.2 volts?

B4 CHECK VOLTAGE AND GROUND TO THE TCCM
Yes
Disconnect: TCCM C2371B.
Ignition ON. No
Measure the voltage between TCCM C2371B-3, GO to B5 .
circuit GD133 (BK), harness side and TCCM
C2371B-7, circuit SBB27 (BU/RD), harness side.

B5 CHECK VOLTAGE TO THE TCCM
Yes
Measure the voltage between TCCM C2371B-7, REPAIR circuit GD133 (BK). CLEAR
circuit SBB27 (BU/RD), harness side and ground. all CMDTCs . TEST the system for
normal operation.
No
VERIFY BJB fuse 27 (20A) is OK. If
OK, REPAIR circuit SBB27 (BU/RD).
If not OK, REFER to the Wiring
Diagrams manual to identify possible
causes of the circuit short. CLEAR all
CMDTCs. TEST the system for normal
operation.
B6 CHECK FOR CORRECT TCCM OPERATION
Yes
Ignition OFF. INSTALL a new TCCM . REFER to
Disconnect all TCCM connectors. 4X4 Control Module in this section.
Check for: CLEAR all CMDTCs . TEST the system
damaged pins
pushed-out pins No
Connect all TCCM connectors and make sure they are The system is operating correctly at this
seated correctly. time. The concern may have been caused
PINPOINT TEST B: DTC P0562:00 OR P0563:00 2887

Operate the system and determine if the concern is still by a loose or corroded connector.
present. ADDRESS the root cause of the
Is the concern still present? connector concern.
Pinpoint Test C: The Front Axle Does Not Engage/Disengage Correctly
Normal Operation
In 4X2 mode, the Transfer Case Control Module (TCCM) supplies a ground path to the Integrated Wheel End
(IWE) solenoid to apply vacuum to the IWEs (disengaging the front hubs from the front axle). In 4X4 mode
and 4X4 AUTO modes, the TCCM does not supply the ground path to the IWE solenoid, vacuum is not
applied to the IWEs and an internal spring keeps the hubs engaged.
DTC C1979:11 (IWE Solenoid Circuit Failure: Circuit Short To Ground) - Fault sets when TCCM
C2371A pin 6 detects a short to ground. Fault results in IWEs hubs disengaged all the time.
DTC C1979:12 (IWE Solenoid Circuit Failure: Circuit Short To Battery) - Fault sets when TCCM
C2371A pin 6 detects a short to voltage. Fault results in IWEs hubs engaged all the time.
DTC C1979:13 (IWE Solenoid Circuit Failure: Circuit Open) - Fault sets when TCCM C2371A pin 6
detects an open circuit. Fault results in IWEs hubs engaged all the time.

Vacuum leaks
IWEs
IWE solenoid
Transfer case
Front axle assembly
TCCM
PINPOINT TEST C: THE FRONT AXLE DOES NOT ENGAGE/DISENGAGE CORRECTLY
Test Step
C1 CHECK FOR TCCM DTCs
Yes
Ignition ON. For DTC C1979:11, GO to C19 .
Self-Test - TCCM . For DTC C1979:12, GO to C18 .
Are any DTCs present?
For DTC C1979:13, GO to C20 .
For all other DTCs, REFER to the

Transfer Case Control Module (TCCM)
No
GO to C2 .
C2 CHECK FOR GRINDING NOISES AT HIGH
SPEEDS

With the vehicle warm and the MSS in 2H mode, drive Yes
the vehicle at sustained WOT for 5 seconds. GO to Pinpoint Test H .
Is there a grinding noise from the axle system
during WOT ? No
GO to C3 .
C3 CHECK TCCM OPERATION
Yes
Monitor the 4X4 indicator on the IC while moving the
MSS between 2H and 4H modes. No
Does the 4X4 indicator illuminate when the MSS is GO to Pinpoint Test D .
in the 4H position and turn off when the MSS is in
the 2H position?
C4 CHECK THE IWE DISENGAGEMENT
Yes
NOTE: The engine must be idling during the GO to C8 .
following steps to supply the vacuum required for the
IWEs to engage and disengage. No
GO to C5 .
With the vehicle in NEUTRAL, position it on a hoist.
Place the MSS in 2H.
Start the engine.
Rotate the LH front tire one revolution forward and
one revolution backward while observing the LH front
halfshaft.
Rotate the RH front tire one revolution forward and
one revolution backward while observing the RH front
halfshaft.
Did either front halfshaft rotate?
C5 CHECK THE IWE ENGAGEMENT
Yes
With the engine running, place the MSS in 4H. The front axle is operating properly at
Rotate the LF tire one revolution forward and one this time. CARRY OUT the 4WD
revolution backward while observing the LF halfshaft. Functional Test. GO to Pinpoint Test I .
Rotate the RF tire one revolution forward and one
revolution backward while observing the RF halfshaft. No
Did both front halfshafts rotate? GO to C6 .
C6 CHECK THE IWE SOLENOID OUTPUT IN 4H
Yes
Disconnect the output vacuum line at the IWE The IWE is mechanically stuck in the
solenoid. disengaged position. INSTALL a new
With the engine running and the MSS in 4H, measure IWE on the halfshaft(s) that did not
the vacuum at the output port of the IWE solenoid. rotate. REFER to Integrated Wheel End
Is the vacuum less than 25 mm (1 in) Hg? (IWE) in this section. TEST the system
No
GO to C7 .
C7 CHECK THE IWE SOLENOID
Yes
PINPOINT TEST C: THE FRONT AXLE DOES NOT ENGAGE/DISENGAGE CORRECTLY 2889
Disconnect: IWE Solenoid C1157.

Start the engine. No
With the engine running, measure the vacuum at the INSTALL a new IWE solenoid. TEST
output port of the IWE solenoid. the system for normal operation.
Is the vacuum less than 25 mm (1 in) Hg?
C8 CHECK THE IWE SOLENOID OUTPUT VACUUM
IN 2H
Yes
Disconnect the output vacuum line at the IWE GO to C11 .
solenoid.
With the engine running and the MSS in 2H, measure No
the vacuum at the output port of the IWE solenoid. GO to C9 .
Is the vacuum greater than 254 mm (10 in) Hg?
C9 CHECK THE IWE SOLENOID INPUT VACUUM
Yes
Disconnect the supply vacuum line at the IWE GO to C20 .
solenoid.
With the engine running, measure the supply line No
vacuum to the IWE solenoid. GO to C10 .
C10 CHECK THE VACUUM RESERVOIR
Yes
Ignition OFF. REPAIR or INSTALL new vacuum
With the source vacuum line still disconnected, lines or INSTALL a check valve. TEST
connect a vacuum pump to the vacuum port on the the system for normal operation.
vacuum reservoir and apply 508 mm (20 in) Hg of
vacuum. No
Does the vacuum maintain or drop less than 25 mm INSTALL a new vacuum reservoir.
(1 in) Hg per minute? TEST the system for normal operation.
C11 CHECK THE IWE VACUUM LINES
Yes
Disconnect the output vacuum line from the IWE
solenoid. No
Disconnect and plug the LH and RH IWE vacuum GO to C12 .
lines at the IWEs .
Connect a vacuum pump to the IWE output vacuum
circuit at the IWE solenoid connection. Apply 508 mm
(20 in) Hg of vacuum and observe the vacuum reading.
Does the vacuum drop more than 25 mm (1 in) Hg
per minute?
C12 CHECK THE LH IWE VACUUM LINE FOR AN
OBSTRUCTION
Yes
REMOVE the plug from the vacuum line at the LH INSTALL a new vacuum line. CLEAR
IWE . the DTCs. TEST the system for normal
Connect a hand vacuum pump to the LH IWE vacuum operation.
line and attempt to draw a vacuum on the line.
Did the vacuum pump draw a vacuum on the LH No
IWE vacuum line? GO to C13 .
C13 CHECK THE RH IWE VACUUM LINE FOR AN
OBSTRUCTION
REMOVE the plug from the vacuum line at the RH Yes

IWE . INSTALL a new vacuum line. CLEAR
Connect a vacuum pump to the RH IWE vacuum line the DTCs. TEST the system for normal
and attempt to draw a vacuum on the line. operation.
Did the vacuum pump draw a vacuum on the RH
IWE vacuum line? No
GO to C14 .
C14 CHECK THE RH IWE LEAK RATE
Yes
Apply 508 mm (20 in) Hg of vacuum to the RH IWE GO to C15 .
port and observe vacuum reading.
Does the vacuum maintain or drop less than 25 mm No
(1 in) Hg per minute? INSTALL a new RH IWE . REFER to
Integrated Wheel End (IWE) in this
operation.
C15 CHECK THE RH IWE OPERATION
Yes
Connect a vacuum pump with gauge to the larger port CONNECT the vacuum line to the RH
of the RH IWE . IWE . GO to C16 .
Observe the RH halfshaft while rotating the RH front
tire. Apply between 152 and 203 mm (6 to 8 in) Hg of No
vacuum and release the vacuum to manually disengage INSTALL a new RH IWE . REFER to
and engage the RH IWE . Integrated Wheel End (IWE) in this
Did the RH IWE disengage between 152 and 203 section. TEST the system for normal
mm (6 to 8 in) Hg and engage when the vacuum is operation.
released?
C16 CHECK THE LH IWE LEAK RATE
Yes
Disconnect the vacuum line from the larger port at the GO to C17 .
LH IWE .
Apply 508 mm (20 in) Hg of vacuum to the LH IWE No
port and observe vacuum reading. INSTALL a new LH IWE . REFER to
Does the vacuum maintain or drop less than 25 mm Integrated Wheel End (IWE) in this
(1 in) Hg per minute? section. TEST the system for normal
operation.
C17 CHECK THE LH IWE OPERATION
Yes
Connect a vacuum pump with gauge to the larger port CONNECT the vacuum line to the LH
of the LH IWE . IWE . GO to C18 .
Observe the LH halfshaft while rotating the LH front
vacuum and release the vacuum to manually disengage INSTALL a new LH IWE . REFER to
and engage the LH IWE . Integrated Wheel End (IWE) in this
Did the LH IWE disengage between 152 and 203 section. CLEAR the DTCs. TEST the
mm (6 to 8 in) Hg and engage when the vacuum is system for normal operation.
released?
C18 CHECK THE IWE SOLENOID CONTROL
Ignition OFF. Yes

Disconnect: IWE Solenoid C1157. REPAIR circuit CCF05 (BN/BU).
Disconnect: TCCM C2371A. CLEAR the DTCs. TEST the system for
Measure the voltage between IWE solenoid C1157-2,
circuit CCF05 (BN/BU), harness side and ground. No
GO to C19 .

Yes
Disconnect: TCCM C2371A. No
Measure the resistance between solenoid C1157-2, REPAIR circuit CCF05 (BN/BU).
circuit CCF05 (BN/BU), harness side and ground. CLEAR the DTCs. TEST the system for
normal operation.

C20 CHECK THE IWE SOLENOID RESISTANCE
Yes
NOTE: If the temperatures (either ambient or in the GO to C21 .
engine compartment) are exceptionally high, a higher
than normal resistance reading could result. A lower No
temperature could result in a lower resistance reading. INSTALL a new IWE solenoid. CLEAR
the DTCs. TEST the system for normal
Ignition OFF. operation.
Measure the resistance between IWE solenoid C1157
pins 1 and 2, component side.

C21 CHECK FOR VOLTAGE TO THE IWE
SOLENOID
Yes
Measure the voltage between IWE solenoid C1157-1, GO to C22 .
circuit SBB29 (GY/RD), harness side and ground.
No
CHECK Battery Junction Box (BJB)
fuse 29 (20A). If OK, REPAIR circuit
SBB29 (GY/RD). If not OK, REFER to
the Wiring Diagrams manual to identify
CLEAR the DTCs. TEST the system for
normal operation.

CIRCUIT FOR AN OPEN
Yes
Disconnect: TCCM C2371A.
Measure the resistance between IWE solenoid No
C1157-2, circuit CCF05 (BN/BU), harness side and REPAIR circuit CCF05 (BN/BU).
TCCM C2371A-6, circuit CCF05 (BN/BU), harness CLEAR the DTCs. TEST the system for

C23 CHECK FOR CORRECT TCCM OPERATION
Yes
corrosion
damaged pins No
pushed-out pins The system is operating correctly at this
Connect all TCCM connectors and make sure they are time. Concern may have been caused by
seated correctly. a loose or corroded connector.
Operate the system and verify the concern is still ADDRESS the root cause of the
present. connector or pin issues.
Pinpoint Test D: The Vehicle Does Not Shift Between 4X4 AUTO and 4X4 Modes Correctly
Normal Operation
The Mode Select Switch (MSS) communicates the operator's choice to the Transfer Case Control Module
(TCCM). The TCCM then controls the transfer case clutch and Integrated Wheel End (IWE) as necessary. If
the vehicle is not responding to the operator's intentions, systematically check the necessary inputs and
outputs of the TCCM , components of the transfer case, IWE components and halfshafts. Check all circuits for
opens and shorts to power or ground.
DTC P1812:00 (4-Wheel Drive Mode Select Circuit Failure: No Sub Type Information) - Open
circuit or short to battery sensed by the TCCM C2371A pin 16.
DTC P1815:00 (4-Wheel Drive Mode Select Short Circuit To Ground: No Sub Type Information) -
Short to ground sensed by the TCCM C2371A pin 16.

Four-Wheel Drive (4WD) indicator
Ignition switch
Transfer case clutch
Transfer case
PCM
TCCM
PINPOINT TEST D: THE VEHICLE DOES NOT SHIFT BETWEEN 4X4 AUTO AND 4X4 MODES CORRECTLY

D1 CHECK FOR TCCM DTCs
Yes
Ignition ON. If DTC P1812:00, GO to D7 . If DTC
Enter the following diagnostic mode on the scan P1815:00, GO to D6 . For all other DTCs,
tool: Self-Test - TCCM . REFER to the Transfer Case Control
Are DTCs retrieved? Module (TCCM) DTC Chart in this section
for diagnosis.
No
GO to D2 .
D2 CHECK THE 4X4 MODE INDICATOR
Yes
Select 4X4 mode and observe the IC . GO to D11 .
Does the IC indicator lamp indicate 4H (4X4)

mode? No
GO to D3 .
D3 CHECK THE TCCM IGNITION POSITION
(KEY_POS_4X4) PID
Yes
Enter the following diagnostic mode on the scan GO to D4 .
tool: DataLogger - TCCM .
Monitor the (KEY_POS_4X4) PID while cycling No
the ignition through each position: REFER to Section 211-05 to diagnose the
Does the ignition position PID match the ignition nition switch concern.
switch positions?
D4 CHECK THE TCCM 4WD SWITCH STATUS
(4X4_SW) PID
Yes
Monitor 4X4_SW PID while cycling through each No
MSS position. GO to D5 .
MSS Position PID Status

4X2 2WD
4X4 AUTO Automatic
4X4 4WD-HIGH
Does each PID status agree with each MSS

position?
D5 CHECK THE MSS RESISTANCE VALUES
Yes
Disconnect: MSS C2071.
NOTE: The MSS is a momentary switch, the No
button must be pressed and held when measuring INSTALL a new MSS . CLEAR the DTCs.
resistance of the MSS . TEST the system for normal operation.
Measure the resistance between MSS C2071 pins 2
and 3, component side while selecting the different
positions. Refer to the following chart.
MSS Position Resistance 1%

4X2 267 - 273 ohms
4X4 AUTO 129 - 131 ohms
4X4 61 - 63 ohms
PINPOINT TEST D: THE VEHICLE DOES NOT SHIFT BETWEEN 4X4 AUTO AND 4X4 MODES
2895
CORREC
Are the resistance values within specification?

D6 CHECK THE MSS CONTROL AND RETURN
Yes
Disconnect: MSS C2071 .
Measure the resistance between MSS C2071-2, REPAIR the affected circuit(s). CLEAR the
circuit RCF13 (WH/BN), harness side and ground; DTCs. TEST the system for normal
and between MSS C2071-3 circuit CCF13 operation.
(WH/BU), harness side and ground.

CIRCUITS FOR SHORT TO VOLTAGE
Yes
Disconnect: MSS C2071. DTCs. TEST the system for normal
Disconnect: TCCM C2371A. operation.
Ignition ON.
Measure the voltage between MSS C2071-2, circuit No
RCF13 (WH/BN), harness side and ground; and GO to D8 .
between MSS C2071-3, circuit CCF13 (WH/BU),

2896
CORREC
Ignition OFF. Yes

Measure the resistance between MSS C2071 and GO to D9 .
TCCM C2371A as shown below:
No
DTCs. TEST the system for normal
operation.
MSS Circuit TCCM
C2071-2 RCF13 (WH/BN) C2371A-14
C2071-3 CCF13 (WH/BU) C2371A-16

Yes
Measure the resistance between MSS C2071-2, GO to D10 .
circuit RCF13 (WH/BN), harness side and MSS
C2071-3, circuit CCF13 (WH/BU), harness side. No
DTCs.

D10 CHECK THE 4WD PWM CLUTCH STATUS
(4WD_CLTCH_OUT) PID
Yes
Connect: MSS C2071. GO to D24 .
Connect: TCCM C2371A.
Ignition ON. No
Enter the following diagnostic mode on the scan DIAGNOSE the PCM. REFER to
tool: DataLogger - TCCM . Powertrain Control/Emissions Diagnosis
Monitor the 4WD_CLTCH_OUT PID. (PC/ED) manual and the HS-CAN. REFER
Does the PID read at least 12% at closed to Section 418-00. CLEAR the DTCs.
throttle? TEST the system for normal operation.
D11 CHECK FOR 4X4 MODE WIND-UP
Yes
Select 4X4 mode. GO to D15 .
2897
CORREC
Drive the vehicle on a dry, hard surface in turns No

while applying the throttle. GO to D12 .
Is wind-up present in turns?
(4WD_CLTCH_OUT) PID AT WOT
Yes
Monitor the 4WD_CLTCH_OUT PID at Wide No
Open Throttle (WOT), Key ON Engine OFF GO to D13 .
(KOEO).
Does the PID read 98% at WOT ?
D13 CHECK THE ABSOLUTE THROTTLE
POSITION (TP_TCCM) PID
Yes
GO to D14 .
NOTE: The TP_TCCM PID is Accelerator Pedal
Position (APP) as communicated by the PCM via No
HS-CAN . DIAGNOSE the PCM, REFER to
Slowly move the accelerator pedal from closed Powertrain Control/Emissions Diagnosis
throttle to WOT and observe the TP_TCCM PID. (PC/ED) manual. To DIAGNOSE the
Does the TP_TCCM PID vary between 0% at HS-CAN , REFER to Section 418-00 .
closed throttle and 100% at WOT ? CLEAR the DTCs. TEST the system for
normal operation.
D14 CHECK FOR TRANSFER CASE CLUTCH
ENGAGEMENT WITH THE 4WD PWM CLUTCH
STATUS (4WD_CLTCH_OUT) ACTIVE COMMAND
AND 4WD PWM CLUTCH STATUS
(4WD_CLTCH_OUT) PID
Yes
Using the 4WD_CLTCH_OUT active command, END the active command. CHECK the
engage the transfer case clutch to 100% while transfer case. REFER to Section 308-07B .
monitoring the 4WD_CLTCH_OUT PID. CLEAR the DTCs. TEST the system for
Does the PID read 100%? normal operation.
No
GO to D18 .
D15 CHECK 4WD INDICATOR IN AUTO MODE
Yes
Select 4X4 AUTO mode and observe the IC . GO to D16 .
Does the IC indicator lamp indicate 4X4 AUTO
mode? No
D16 CHECK FOR WIND-UP IN AUTO MODE
Yes
Drive the vehicle on a dry, hard surface in turns GO to D17 .
while applying the throttle.
Is wind-up present in turns? No
The system is operating correctly. CLEAR
operation.
2898
CORREC

(4WD_CLTCH_OUT) PID
Yes
Monitor the 4WD_CLTCH_OUT PID at closed No
throttle, KOEO . GO to D20 .
Does the PID indicate 2 to 4% clutch application
at closed throttle?
D18 CHECK VOLTAGE ON THE CLUTCH POWER
CIRCUIT USING THE 4WD PWM CLUTCH STATUS
(4WD_CLTCH_OUT) ACTIVE COMMAND
2899
CORREC
Four Wheel Drive (4WD) Systems - 2-Speed Torque-On-Demand
Special Tool(s)
Flex Probe Kit



The Expedition is equipped with an automatic electronic-shift system that allows the operator to choose
between 2-Wheel Drive (2WD) and 3 different Four-Wheel Drive (4WD) modes. The operator can switch
between 2WD
Wheel slip is sensed by monitoring the average front and rear wheel speeds. Based on steering wheel angle,
Accelerator Pedal Position (APP) and wheel slip, a Pulse-Width Modulation (PWM) signal is transmitted to
the transfer case as torque is required.
The Transfer Case Control Module (TCCM) will provide the ABS with current clutch duty cycle and whether
or not ABS may command the clutch duty cycle.
The brake subsystem sends the following information signals to the 4WD system over the High Speed
Controller Area Network (HS-CAN):
Occurrences of brake events and failures. Refer to Section 206-09 .

Steering wheel angle status. Refer to Section 206-09 .
Wheel speeds. Refer to Section 206-09 .
A concern with any of the above listed brake system signals HS-CAN will affect operation of the 4WD
system.
The APP output signal is provided to the TCCM from the PCM. This signal is used by the TCCM in
controlling the transfer case clutch.
The shift motor sense plate, an integral part of the shift motor assembly, informs the TCCM of the transfer
case position.
The electric shift motor is mounted externally to the transfer case. It drives a rotary cam which moves the
range fork within the transfer case between the HIGH range (2H, 4A and 4H) and LOW range (4L) positions.
The TCCM sends a duty cycle command to the clutch coil which activates the clutch within the transfer case.

The TCCM varies the torque sent to the front driveline by controlling the transfer case clutch. At rest and
under cruising conditions, the TCCM activates the transfer case clutch a minimum duty cycle (percentage of
time the clutch is turned on), which allows for the slight difference between the front and rear driveshafts
which normally occurs when negotiating a corner on dry pavement. Under any of the following conditions,
the TCCM will increase the duty cycle in order to prevent or control slip:
Slip is detected
Heavy acceleration (throttle position)
Straight-ahead steering wheel angle
Feature inputs:

Steering wheel angle (from the ABS module)
Transmission Range (TR) position (from the PCM)
Transmission output torque (from the PCM)
Wheel speed signal (transmitted from the ABS module)
APP (from the PCM)
Transfer case shift motor contact plate position inputs A, B, C, D
Feature outputs:
PWM signal to the transfer case clutch

4WD message center indicators
Transfer case shift motor outputs
Shifts between 4X4 AUTO (4A) and 4X4 (4H) modes can be made at any speed. Listed below are the inputs
and outputs needed by the TCCM to execute a change between any of these modes.
Feature inputs:
Wheel speed signal

APP (from the PCM)
MSS
Feature outputs:

When shifting into or out of 4X4 LOW (4L) mode, the TCCM requires that the vehicle speed is less than 3
km/h (2 mph) and the transmission is in NEUTRAL.
Feature inputs:
APP (from the PCM)

MSS
Transfer case shift motor encoder contact plate position inputs A, B, C, D
Wheel speed signal (transmitted from ABS module)
Feature outputs:


Halfshafts Power Distribution Box (PDB) fuses:

Integrated Wheel 20 (20A)
End (IWE) 27 (20A)
Shift motor 29 (20A)
Driveshaft and Smart Junction Box (SJB) mini fuse 35
U-joints (10A)
Vacuum leaks Wiring harness
Fluid leaks Mode Select Switch (MSS)
Matching tire sizes Synchronization clutch
Transfer case Connector(s)
IWE vacuum solenoid
Circuitry

6. NOTE: Before carrying out the self-test, make sure that:
ignition is in RUN.
4A mode is selected (or the last mode selected before starting the self-test).
If the scan tool does not communicate with the vehicle:
verify the ignition is in the ON position.

418-00 .
(CMDTCs).
8. Clear the DTCs and carry out the self-test diagnostics for the TCCM .
9. If the DTCs retrieved are related to the concern, go to the Transfer Case Control Module (TCCM)
DTC Chart. For all other DTCs, refer to Section 419-10 .
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart - Four Wheel Drive (4WD) or
GO to Symptom Chart - NVH .
DTC Charts
Transfer Case Control Module (TCCM) DTC Chart

C1729:00 Transfer Case Unable To Transition GO to Pinpoint Test P .
Between 4H and 4L: No Sub Type
Information
C1979:11 IWE Solenoid Circuit Failure: Circuit GO to Pinpoint Test N .
Short To Ground
Short To Battery
Open
P0562:00 System Voltage Low: No Sub Type GO to Pinpoint Test B .
Information
P0563:00 System Voltage High: No Sub Type GO to Pinpoint Test B .
Information
P1812:00 4-Wheel Drive Mode Select Circuit GO to Pinpoint Test X .
Failure: No Sub Type Information
P1815:00 4-Wheel Drive Mode Select Short To GO to Pinpoint Test X .
P1825:00 4-Wheel Drive Clutch Relay Open GO to Pinpoint Test Q .
Circuit: No Sub Type Information
P1826:00 4-Wheel Drive Low Clutch Relay GO to Pinpoint Test Q .
Circuit To Battery: No Sub Type
Information
P1827:00 4-Wheel Drive Low Clutch Relay GO to Pinpoint Test Q .
Circuit To Ground: No Sub Type
Information
P1839:00 GO to Pinpoint Test X .

Transfer Case Shift Motor Open

Circuit: No Sub Type Information
P1840:00 Transfer Case Shift Motor Short Circuit GO to Pinpoint Test X .
To Battery: No Sub Type Information
P1841:00 Transfer Case Shift Motor Short Circuit GO to Pinpoint Test X .
To Ground: No Sub Type Information
P1849:00 Transfer Case Contact Plate 'A' Short GO to Pinpoint Test X .
Information
P1853:00 Transfer Case Contact Plate 'B' Short GO to Pinpoint Test X .
Information
P1857:00 Transfer Case Contact Plate 'C' Short GO to Pinpoint Test X .
Information
P1861:00 Transfer Case Contact Plate 'D' Short GO to Pinpoint Test X .
Information
P1867:00 Transfer Case Contact Plate General GO to Pinpoint Test X .
Circuit Failure: No Sub Type
Information
P1886:00 4X4 Initialization Failure: No Sub Type CLEAR the DTC. REPEAT the self-test. If the DTC still
Information reports, CONFIRM the Transfer Case Control Module
(TCCM) part number is correct for the vehicle.
P1891:00 Transfer Case Contact Plate Ground GO to Pinpoint Test X .
Return Open Circuit: No Sub Type
Information
U0100:00 Lost Communication With ECM/PCM REFER to Section 418-00 to diagnose lost
"A": No Sub Type Information communication with the PCM.
U0121:00 Lost Communication With Anti-Lock REFER to Section 418-00 to diagnose lost
Brake System (ABS) Control Module: communication with the ABS module.
U0418:00 Invalid Data Received From Brake REFER to Section 206-09 to diagnose the wheel speed
System Control Module: No Sub Type sensor concern.
Information
U3000:04 Control Module: System Internal CLEAR the DTC. REPEAT the self-test. If DTC
Failure U3000:04 is retrieved, INSTALL a new TCCM . REFER
to 4X4 Control Module in this section. REPEAT the
self-test.
U3000:41 Control Module: General Checksum CLEAR the DTC. REPEAT the self-test. If DTC
self-test.
U3000:46 Control Module: Calibration / CLEAR the DTC. REPEAT the self-test. If DTC
Parameter Memory Failure U3000:46 is retrieved, INSTALL a new TCCM . REFER
self-test.
U3000:49 Control Module: Internal Electronic CLEAR the DTC. REPEAT the self-test. If DTC

self-test.
U300D:11 Ignition Input On/Start: Circuit Short GO to Pinpoint Test A .
To Ground
Symptom Chart - NVH
Symptom Chart - NVH

Grinding noise during Four-Wheel Drive (4WD) system engagement, especially at high speeds
Front halfshaft speeds not turning at the same speed

Sychronization clutch
Vehicle Pulsates or Shudders in a Straight Line (Straightline Driveline Wind-up)

GO to Pinpoint Test S .
The front axle makes noise in 2H mode only and generally under heavy throttle
Vacuum leaks
Vacuum lines
Vacuum check valves
Vacuum reservoir
IWE
GO to Pinpoint Test T .
The transfer case makes noise
Tire inflation pressure

Tire and wheel size
MAKE SURE that all tires and wheels are the same size and that the inflation pressures are correct.
Tire tread wear
CHECK tire tread wear to see if there is more than 0.15 mm (0.06 in) difference in tread wear
between front and rear. INTERCHANGE one front wheel and one rear wheel. ROAD TEST again.
Internal components
OPERATE the vehicle in all transmission gears. If there is noise in the transmission in NEUTRAL, or
in some gears and not in others, REMOVE and REPAIR the transmission. REFER to Section 307-01 .
If there is noise in all gears, DISASSEMBLE the transfer case. REFER to Section 308-07B . CHECK
the planetary gears, the bearings, the upper and lower drive sprockets and drive chain for damage.
INSTALL new parts as necessary.
Fluid level
FILL to the correct level and with the specified fluid. REFER to Section 308-07B .
Transfer case whine - noise at all ranges
Incorrect fluid level or fluid quality

Worn oil pump
Under-inflated or oversized tires
CHECK that the transfer case is filled to the correct level and with the specified fluid. REFER to
Section 308-07B .
DISASSEMBLE the transfer case. CHECK the oil pump for wear or damage. REPAIR as necessary.
CONFIRM that the tires and wheels are correct for the vehicle. CHECK that the tire inflation
pressures are correct.
Transfer case growl/rumb - noise at all ranges
Damaged or worn bearings or planetary gear
DISASSEMBLE the transfer case. CHECK the bearings or planetary gear for wear or damage.
REPAIR as necessary. REFER to Section 308-07B .
Transfer case scraping/grating - noise at all ranges
Excessively stretched drive chain hitting the case
DISASSEMBLE the transfer case. CHECK the drive chain for wear or damage. REPAIR as
necessary. REFER to Section 308-07B .
Transfer case howl/hum - noise at all ranges or 4H only
Worn or damaged sun (input) gear, clutch pack (intermediate) gear or output shaft gear
DISASSEMBLE the transfer case. CHECK the gears for wear or damage. REPAIR as necessary.

Vehicle binds in a turn/resists turning/pulsates in a straightline in 4WD mode

Throttle position failure
Transfer case clutch
Circuitry
TCCM
GO to Pinpoint Test W .
Pinpoint Tests
Pinpoint Test N: The Front Axle Does Not Engage/Disengage Correctly
Refer to Wiring Diagrams Cell 34 , Four-Wheel Drive Systems for schematic and connector information.
Normal Operation
In 2H mode, the Transfer Case Control Module (TCCM) supplies a ground path to the Integrated Wheel End
(IWE) solenoid to apply vacuum to the IWEs (disengaging the front hubs from the front axle). In 4H or 4L
modes, the TCCM does not supply the ground path to the IWE solenoid, vacuum is not applied to the IWEs
and an internal spring in the IWEs keeps the hubs engaged.
DTC C1979:11 (IWE Solenoid Circuit Failure: Circuit Short To Ground) - Fault sets when TCCM
C2371A pin 6 detects a short to ground. Fault results in IWEs hubs disengaged all the time.
DTC C1979:12 (IWE Solenoid Circuit Failure: Circuit Short To Battery) - Fault sets when TCCM
C2371A pin 6 detects a short to voltage. Fault results in IWEs hubs engaged all the time.
DTC C1979:13 (IWE Solenoid Circuiilure: Circuit Open) - Fault sets when TCCM C2371A pin 6
detects an open circuit. Fault results in IWEs hubs engaged all the time.

Vacuum leaks
IWEs
IWE solenoid
Transfer case
Front axle assembly
TCCM
PINPOINT TEST N: THE FRONT AXLE DOES NOT ENGAGE/DISENGAGE CORRECTLY
WARNING: When directed to drive the vehicle as part of this test, drive the vehicle on a hard
surface in an area without traffic to prevent a crash. Failure to follow these instructions may result in
personal injury.

N1 CHECK FOR DTCs

Yes
Ignition ON. For DTC C1979:11, GO to N19 .
Self-Test - TCCM . For DTC C1979:12, GO to N18 .
For DTC C1979:13, GO to N20 .

DTC Chart.
No
GO to N2 .
N2 CHECK FOR GRINDING NOISES AT HIGH
SPEEDS
Yes
With the vehicle warm and the MSS in 2H mode, drive GO to Pinpoint Test T .
the vehicle at sustained WOT for 5 seconds.
Is there a grinding noise from the axle system No
during WOT ? GO to N3 .
N3 CHECK TCCM OPERATION
Yes
Ignition ON. GO to N4 .
Monitor the 4X4 indicator on the IPC while moving
the MSS between 2H and 4H modes. No
Does the 4X4 indicator illuminate when the MSS is GO to Pinpoint Test X .
in the 4H position and turn off when the MSS is in
the 2H position?
N4 CHECK THE IWE DISENGAGEMENT
Yes
NOTE: The engine must be idling during the GO to N8 .
following steps to supply the vacuum required for the
IWEs to engage and disengage. No
GO to N5 .
Place the MSS in 2H.
Start the engine.
Rotate the LH front tire one revolution forward and
one revolution backward while observing the LH front
halfshaft.
halfshaft.
Did either front halfshaft rotate?
N5 CHECK THE IWE ENGAGEMENT
Yes
With the vehicle in NEUTRAL, position it on a hoist. The front axle is operating properly at
Refer to Section 100-02 . this time. CARRY OUT the 4WD
With the engine running, place the MSS in 4H. Functional Test. GO to Pinpoint Test U .
PINPOINT TEST N: THE FRONT AXLE DOES NOT ENGAGE/DISENGAGE CORRECTLY 2908
Rotate the LH front tire one revolution forward and No

one revolution backward while observing the LH front GO to N6 .
halfshaft.
halfshaft.
Did both front halfshafts rotate?
N6 CHECK THE IWE SOLENOID OUTPUT IN 4H
Yes
Disconnect the output vacuum line at the IWE The IWE is mechanically stuck in the
solenoid. disengaged position. INSTALL a new
With the engine running and the MSS in 4H, measure IWE on the halfshaft(s) that did not
the vacuum at the output port of the IWE solenoid. rotate. REFER to Integrated Wheel End
Is the vacuum less than 25 mm (1 in) Hg? (IWE) in this section. TEST the system
No
GO to N7 .
N7 CHECK THE IWE SOLENOID
Yes
Ignition OFF. GO to N20 .
Measure the vacuum at the output port of the IWE INSTALL a new IWE solenoid. TEST
solenoid. the system for normal operation.
Is the vacuum less than 25 mm (1 in) Hg?
N8 CHECK THE IWE SOLENOID OUTPUT VACUUM
IN 2H
Yes
Disconnect the output vacuum line at the IWE GO to N11 .
solenoid.
With the engine running and the MSS in 2H, measure No
the vacuum at the output port of the IWE solenoid. GO to N9 .
N9 CHECK THE IWE SOLENOID INPUT VACUUM
Yes
Disconnect the supply vacuum line at the IWE GO to N20 .
solenoid.
With the engine running, measure the supply line No
vacuum to the IWE solenoid. GO to N10 .
N10 CHECK THE VACUUM RESERVOIR
Yes
Ignition OFF. REPAIR or INSTALL new vacuum
With the source vacuum line still disconnected, lines or INSTALL a check valve. TEST
connect a vacuum pump to the vacuum port on the the system for normal operation.
vacuum reservoir and apply 508 mm (20 in) Hg of
vacuum. No
Does the vacuum maintain or drop less than 25 mm INSTALL a new vacuum reservoir.
(1 in) Hg per minute? TEST the system for normal operation.
N11 CHECK THE IWE VACUUM LINES
Ignition OFF. Yes

Disconnect the output vacuum line from the IWE GO to N14 .
solenoid.
Disconnect and plug the LH and RH IWE vacuum No
lines at the IWEs . GO to N12 .
Connect a vacuum pump to the IWE output vacuum
circuit at the IWE solenoid connection. Apply 508 mm
(20 in) Hg of vacuum and observe the vacuum reading.
Does the vacuum drop more than 25 mm (1 in) Hg
per minute?
N12 CHECK THE LH IWE VACUUM LINE FOR AN
OBSTRUCTION
Yes
REMOVE the plug from the vacuum line at the LH INSTALL a new vacuum line. CLEAR
Connect a hand vacuum pump to the LH IWE vacuum operation.
Did the vacuum pump draw a vacuum on the LH No
IWE vacuum line? GO to N13 .
N13 CHECK THE RH IWE VACUUM LINE FOR AN
OBSTRUCTION
Yes
REMOVE the plug from the vacuum line at the RH INSTALL a new vacuum line. CLEAR
Connect a vacuum pump to the RH IWE vacuum line operation.
and attempt to draw a vacuum on the line.
Did the vacuum pump draw a vacuum on the RH No
IWE vacuum line? GO to N14 .
N14 CHECK THE RH IWE LEAK RATE
Yes
Apply 508 mm (20 in) Hg of vacuum to the RH IWE GO to N15 .
port and observe vacuum reading.
Does the vacuum maintain or drop less than 25 mm No
(1 in) Hg per minute? INSTALL a new RH IWE . REFER to
Integrated Wheel End (IWE) in this
operation.
N15 CHECK THE RH IWE OPERATION
Yes
Connect a vacuum pump with gauge to the larger port CONNECT the vacuum line to the RH
of the RH IWE . IWE . GO to N16 .
Observe the RH halfshaft while rotating the RH front
vacuum and release the vacuum to manually disengage INSTALL a new RH IWE . REFER to
and engage the RH IWE . Integrated Wheel End (IWE) in this
Did the RH IWE disengage between 152 and 203 section. TEST the system for normal
mm (6 to 8 in) Hg and engage when the vacuum is operation.
released?
N16 CHECK THE LH IWE LEAK RATE
Yes
Disconnect the vacuum line from the larger port at the GO to N17 .
LH IWE .
Apply 508 mm (20 in) Hg of vacuum to the LH IWE No

port and observe vacuum reading. INSTALL a new LH IWE . REFER to
Does the vacuum maintain or drop less than 25 mm Integrated Wheel End (IWE) in this
(1 in) Hg per minute? section. TEST the system for normal
operation.
N17 CHECK THE LH IWE OPERATION
Yes
Connect a vacuum pump with gauge to the larger port CONNECT the vacuum line to the LH
of the LH IWE . IWE . GO to N18 .
Observe the LH halfshaft while rotating the LH front
vacuum and release the vacuum to manually disengage INSTALL a new LH IWE . REFER to
and engage the LH IWE . Integrated Wheel End (IWE) in this
Did the LH IWE disengage between 152 and 203 section. CLEAR the DTCs. TEST the
mm (6 to 8 in) Hg and engage when the vacuum is system for normal operation.
released?
N18 CHECK THE IWE SOLENOID CONTROL
Yes
Ignition OFF. REPAIR circuit CCF05 (BN/BU).
Disconnect: IWE Solenoid C1157. CLEAR the DTCs. TEST the system for
Disconnect: TCCM C2371A. normal operation.
Ignition ON.
Measure the voltage between IWE solenoid C1157-2, No
circuit CCF05 (BN/BU), harness side and ground. GO to N19 .

Yes
Measure the resistance between solenoid C1157-2, REPAIR circuit CCF05 (BN/BU).
circuit CCF05 (BN/BU), harness side and ground. CLEAR the DTCs. TEST the system for
normal operation.

N20 CHECK THE IWE SOLENOID RESISTANCE
Yes
NOTE: If the temperatures (either ambient or in the GO to N21 .
engine compartment) are exceptionally high, a higher
than normal resistance reading could result. A lower No
temperature could result in a lower resistance reading. INSTALL a new IWE solenoid. CLEAR
Ignition OFF. operation.
Measure the resistance between IWE solenoid C1157
pins 1 and 2, component side.

N21 CHECK FOR VOLTAGE TO THE IWE
SOLENOID
Yes
Measure the voltage between IWE solenoid C1157-1, GO to N22 .
circuit SBB29 (GY/RD), harness side and ground.
No
CHECK Battery Junction Box (BJB)
fuse 29 (20A). If OK, REPAIR circuit
SBB29 (GY/RD). If not OK, REFER to
the Wiring Diagrams manual to identify
CLEAR the DTCs. TEST the system for
normal operation.

CIRCUIT FOR AN OPEN
Yes
Measure the resistance between IWE solenoid REPAIR circuit CCF05 (BN/BU).
C1157-2, circuit CCF05 (BN/BU), harness side and CLEAR the DTCs. TEST the system for
TCCM C2371A-6, circuit CCF05 (BN/BU), harness normal operation.
side.

N23 CHECK FOR CORRECT TCCM OPERATION
Yes
corrosion
damaged pins No
pushed-out pins The system is operating correctly at this
Connect all TCCM connectors and make sure they are time. Concern may have been caused by
seated correctly. a loose or corroded connector.
Operate the system and verify the concern is still ADDRESS the root cause of the
present. connector or pin issues.
Pinpoint Test O: The Vehicle Does Not Shift Between 4A (4X4 AUTO) and 4H (4X4) Modes Correctly
Normal Operation
In 2H mode, the Transfer Case Control Module (TCCM) supplies a ground path to the Integrated Wheel End
(IWE) solenoid to apply vacuum to the IWEs (disengaging the front hubs from the front axle). In AUTO, 4H
and 4L modes, the TCCM does not supply the ground path to the IWE solenoid, vacuum is not applied to the
IWEs and an internal spring keeps the hubs engaged. Systematically check the necessary inputs and outputs at
the TCCM , internal components of the transfer case, Mode Select Switch (MSS), IWE components and drive
axles.

MSS
IWE
IWE solenoid
Transfer case
Vacuum leaks
Front axle assembly
TCCM
PINPOINT TEST O: THE VEHICLE DOES NOT SHIFT BETWEEN 4A (4X4 AUTO) AND 4H (4X4) MODES
CORRECTLY

O1 CHECK FOR TCCM DTCs

Ignition ON. Yes

Enter the following diagnostic mode on the scan REFER to the TCCM DTC Chart in this
tool: Self-Test - TCCM . section for diagnosis.
Are DTCs retrieved?
No
GO to O2 .
O2 CHECK THE 4H INDICATOR
Yes
Select 4H mode and observe the Instrument GO to O8 .
Cluster (IC).
Does the IC indicator lamp indicate 4H (4X4) N
mode? GO to O3 .
O3 CHECK THE TCCM IGNITION POSITION
(KEY_POS_4X4) PID
Yes
Enter the following diagnostic mode on the scan GO to O4 .
Monitor the KEY_POS_4X4 PID while cycling No
through each position. REFER to Section 211-05 to diagnose the
Does the ignition position PID match the ignition switch concern.
ignition switch positions?
O4 CHECK THE TCCM 4WD SWITCH STATUS
(4X4_SW) PID
Yes
Monitor 4X4_SW PID while cycling the MSS GO to O7 .
through each position.
No
GO to O5 .

2H 2WD
4A Automatic
4H 4WD-HIGH
4L 4WD-LOW
Does each PID status agree with each MSS

position?
O5 CHECK THE MSS RESISTANCE VALUES
Yes
Ignition OFF. GO to O6 .
Measure the resistance between MSS C284 pin 2 No
and pin 3, component side. Refer to the following INSTALL a new MSS . CLEAR the DTCs.
chart: TEST the system for normal operation.
MSS Position Resistance (1%)

2H 619 ohms
PINPOINT TEST O: THE VEHICLE DOES NOT SHIFT BETWEEN 4A (4X4 AUTO) AND 4H (4X4)
2914MODESC
4A 270 ohms
4H 130 ohms
4L 62 ohms

O6 CHECK THE MSS CONTROL AND RETURN
Yes
Disconnect: TCCM C2371A. GO to O19 .
Measure the resistance between TCCM
C2371A-16, circuit CCF13 (WH/BU), harness side No
and MSS C2071-3, circuit CCF13 (WH/BU), REPAIR the affected circuit(s). CLEAR the
harness side. DTCs. TEST the system for normal
operation.
Measure the resistance between TCCM

C2371A-14, circuit RCF13 (WH/BN), harness side
and MSS C2071-2, circuit RCF13 (WH/BN),
harness side.

O7 CHECK THE 4WD PWM CLUTCH STATUS
(4WD_CLTCH_OUT) PID
Yes
Switch the MSS to 4H mode. GO to O19 .
Monitor the 4WD_CLTCH_OUT PID.
Does the 4WD_CLTCH_OUT PID indicate 2 to No
10% clutch application at closed throttle? DIAGNOSE the PCM. REFER to
2915MODESC
Powertrain Control/Emissions Diagnosis

(PC/ED) manual and the HS-CAN. REFER
to Section 418-00. CLEAR the DTCs. TEST
O8 CHECK FOR WIND-UP IN 4H MODE
Yes
Switch the MSS to 4H mode. GO to O13 .
Drive the vehicle on a dry, hard surface in turns
while applying the throttle. No
Is wind-up present in turns? GO to O9 .
(4WD_CLTCH_OUT) PID AT WOT
Yes
Enter the following diagnostic mode on the scan GO to O11 .
Monitor the 4WD_CLTCH_OUT PID at Wide No
Open Throttle (WOT), Key ON Engine OFF GO to O10 .
(KOEO).
Does the 4WD_CLTCH_OUT PID read 98% at
WOT ?
O10 CHECK THE ABSOLUTE THROTTLE
Yes
NOTE: The TP_TCCM PID is Accelerator Pedal GO to O11 .
Position (APP) as communicated by the PCM via
HS-CAN . No
Slowly move the accelerator pedal from closed DIAGNOSE the PCM. REFER to
throttle to WOT and observe the TP_TCCM PID. Powertrain Control/Emissions Diagnosis
Does the TP_TCCM PID vary between 0% at (PC/ED) manual and the HS-CAN . REFER
closed throttle and 100% at WOT ? to Section 418-00 .
O11 CHECK FOR TRANSFER CASE CLUTCH
ENGAGEMENT WITH THE 4WD PWM CLUTCH
AND 4WD PWM CLUTCH STATUS
(4WD_CLTCH_OUT) PID
Yes
engage the transfer case clutch to 100% while transfer case. REFER to Section 308-07B .
monitoring the 4WD_CLTCH_OUT PID.
Does the PID read 100%? No
END the active command. GO to O12 .
O12 CHECK THE IC INDICATOR IN AUTO
MODE
Yes
Select 4A mode and observe the IC . GO to O13 .
Does the IC message center indicate 4A (4X4
AUTO) mode? No
O13 CHECK FOR WIND-UP IN AUTO MODE
Yes
GO to O14 .
2916MODESC
Drive the vehicle on a dry, hard surface in turns

while applying the throttle. No
Is wind-up present in turns? The system is operating correctly.
(4WD_CLTCH_OUT) PID
Yes
Monitor the 4WD_CLTCH_OUT PID at closed GO to O15 .
throttle, KOEO .
Does the 4WD_CLTCH_OUT PID indicate 2 to No
10% clutch application at closed throttle? GO to O17 .
O15 CHECK VOLTAGE ON THE CLUTCH
CONTROL CIRCUIT USING THE 4WD PWM
CLUTCH STATUS (4WD_CLTCH_OUT) ACTIVE
COMMAND
Yes
command the transfer case clutch to 4%. transfer case. REFER to Section 308-07B .
Measure the voltage by carefully back-probing
transfer case C350-16, circuit CCF03 (GY/BN), No
component side and the transfer case housing. GO to O16 .
Is the voltage approximately 0.2 to 0.4 volt?

O16 CHECK CLUTCH CONTROL CIRCUIT FOR
AN OPEN
Yes
Ignition OFF. GO to O17 .
Disconnect: Transfer Case C350.
Disconnect: TCCM C2371B. No
Measure the resistance between transfer case REPAIR circuit CCF03 (GY/BN). CLEAR
C350-16, circuit CCF03 (GY/BN), harness side the DTCs. TEST the system for normal
and TCCM C2371B-1, circuit CCF03 (GY/BN), operation.
harness side.

O17 CHECK THE ABS MODULE WHEEL SPEED
SENSOR PIDs
2917MODESC

tool: DataLogger - ABS Module. GO to O18 .
While driving the vehicle at 30 km/h (18 mph),
monitor the following wheel speed sensor PIDs: No
Left Front Wheel Speed Sensor CHECK the ABS. REFER to Section 206-09
(LF_WSPD) .
Left Rear Wheel Speed Sensor
(LR_WSPD)
(RF_WSPD)
Right Rear Wheel Speed Sensor
(RR_WSPD)
Compare the speedometer reading to the wheel
speed sensor PIDs.
Do the wheel speed sensor PIDs and
speedometer speeds match within 1.5 km/h (1
mph)?
O18 CHECK THE ABSOLUTE THROTTLE
Yes
Enter the followindiagnostic mode on the scan GO to O19 .
Ignition ON. No
Monitor the TP_TCCM PID. DIAGNOSE the PCM. REFER to
NOTE: The TP_TCCM PID is Accelerator Pedal Powertrain Control/Emissions Diagnosis
Position (APP) as communicated by the PCM via (PC/ED) manual and the HS-CAN . REFER
High Speed Controller Area Network (HS-CAN). to Section 418-00 .
Slowly move throttle from closed throttle to Wide
Open Throttle (WOT) and observe the TP_TCCM
PID.
Does the TP_TCCM PID vary between 0% at
closed throttle and 100% at WOT ?
O19 CHECK FOR CORRECT TCCM OPERATION
Yes
Ignition OFF. INSTALL a new TCCM . REFER to 4X4
Disconnect all TCCM connectors. Control Module in this section. CLEAR the
Check for: DTCs. TEST the system for normal
corrosion operation.
damaged pins
pushed-out pins No
Connect all TCCM connectors and make sure they The system is operating correctly at this
are seated correctly. time. Concern may have been caused by a
Operate the system and verify the concern is still loose or corroded connector. ADDRESS the
present. root cause of the connector concern. TEST
Pinpoint Test P: The Vehicle Does Not Shift Between 4H (4X4) and 4L (4X4 Low) Modes Correctly
2918MODESC
Normal Operation
The high-low shift occurs when the reduction shift fork moves the high-low collar to lock the planetary gear
set to the output shaft. The torque transmitted through the sun gear from the input shaft turns the front
planetary gear set assembly. The front planetary gear set assembly, now engaged, provides transfer case speed
reduction. Certain criteria, such as vehicle speed and Transmission Range (TR) selection must be met before
this shift can occur. Systematically check the necessary inputs and outputs of the Transfer Case Control
Module (TCCM), components of the transfer case, Integrated Wheel End (IWE) components and halfshafts.
DTC C1729:00 (Transfer Case Unable to Transition Between 4H and 4L: No Sub Type Information) -
Fault sets when target shift motor position is not reached after the maximum number of allowed
blocked shift retries for 4H to 4L or 4L to 4H. Requested shift motor position is not reached.

Transmission neutral switch
Transmission neutral drag torque
ABS wheel speed inputs
PINPOINT TEST P: THE VEHICLE DOES NOT SHIFT BETWEEN 4H (4X4) AND 4L (4X4 LOW) MODES CORRECTLY
RNING: When directed to drive the vehicle as part of this test, drive the vehicle on a hard surface in
an area without traffic to prevent a crash. Failure to follow these instructions may result in personal
injury.

P1 CHECK FOR DTCs
Yes
Ignition ON. For DTC C1729:00, GO to P2 .
tool: Self-Test - TCCM . For all other DTCs, REFER to the Transfer
Are any DTCs present? Case Control Module (TCCM) DTC Chart in
this section.
No
P2 CHECK THE 2H TO 4H SHIFT
Yes
Drive the vehicle and shift from 2H to 4H. GO to P3 .
Does the vehicle shift between 2H and 4H
correctly? No
P3 CHECK THE 4H TO 4L SHIFT
Yes
NOTE: When switching in or out of 4L, the Transmission neutral drag is excessive. REFER
transmission must be in NEUTRAL and the to Section 307-01 for transmission diagnosis.
vehicle stopped or moving less than 5 km/h (3
mph). No
Drive the vehicle and switch Mode Select GO to P4 .
Switch (MSS) from 4H to 4L.

Does the transfer case shift from 4H to 4L

correctly and the complaint is related to a
clunk noise during the shift?
P4 CHECK THE NEUTRAL INDICATOR
(NEUTRAL) AND ABS MODULE WHEEL SPEED
PIDs
Yes
Enter the following diagnostic mode on the scan If all 5 PIDs are accurate, GO to Pinpoint Test
tool: DataLogger - TCCM . X.
A. Monitor the NEUTRAL PID while shifting
the transmission through gear ranges. No
Enter the following diagnostic mode on the scan A. REFER to Section 307-01 for further
tool: DataLogger - ABS Module. diagnosis of the transmission.
B. Monitor the wheel speed PIDs:
Left Front Wheel Speed Sensor B. REFER to Section 206-09 for further
(LF_WSPD) diagnosis of the ABS system and the HS-CAN
Left Rear Wheel Speed Sensor communication network.
(LR_WSPD)
(RF_WSPD)
(RR_WSPD)
A. Does the NEUTRAL PID indicate True
when the transmission is shifted to
NEUTRAL?
B. Do the wheel speed PIDs indicate 0 km/h

(0 mph)?
Pinpoint Test Q: Four-Wheel Drive (4WD) Does Not Engage at Speed Correctly
Normal Operation
When the operator selects a transfer case mode from 2H mode, the Transfer Case Control Module (TCCM)
engages a clutch for approximately 5 seconds to synchronize the front and rear driveshafts allowing a
mechanical engagement of the transfer case. The TCCM also removes the ground path from the Integrated
Wheel End (IWE) solenoid, which removes vacuum from the IWEs , allowing them to engage the front axle
shaft. Systematically check the necessary inputs and outputs at the TCCM , internal components of the
transfer case, IWE components and drive axles.
DTC P1825:00 (4-Wheel Drive Clutch Relay Open Circuit: No Sub Type Information) - Fault sets
when TCCM C2371B pin 1 detects an open circuit. The TCCM disables transfer case synchronization
clutch operation.
DTC P1826:00 (4-Wheel Drive Low Clutch Relay Circuit To Battery: No Sub Type Information) -
Fault sets when TCCM C2371B pin 1 detects a short to voltage. Transfer case synchronization clutch
operation, though disabled by the TCCM , is fully engaged when this DTC is present.
DTC P1827:00 (4-Wheel Drive Low Clutch Relay Circuit To Ground) - Fault sets when TCCM
C2371B pin 1 detects a short to ground. The TCCM disables transfer case synchronization clutch
operation.
PINPOINT TEST P: THE VEHICLE DOES NOT SHIFT BETWEEN 4H (4X4) AND 4L (4X4 LOW)
2920
MODES C
Transfer case synchronizationh
Transfer case
TCCM
Front axle assembly
PINPOINT TEST Q: 4WD DOES NOT ENGAGE AT SPEED CORRECTLY

Q1 RETRIEVE TCCM DTCs
Yes
Ignition ON. For DTC P1825:00, GO to Q11 .
Self-Test - TCCM . For DTC P1826:00, GO to Q13 .
Are any DTCs retrieved?
For DTC P1827:00, GO to Q10 .
For all other DTCs, GO to the

Transfer Case Control Module
(TCCM) DTC Chart in this section.
No
GO to Q2 .
Q2 CHECK 4X4 MODE ENGAGEMENT AT REST
Yes
Switch the Mode Select Switch (MSS) from 4X2 mode to GO to Q3 .
4X4 mode.
Does 4X4 mode engage at rest correctly? No
Q3 CHECK 4X2 MODE TO 4X4 MODE SHIFT AT SPEED
Yes
Switch the MSS to 4X2 mode. GO to Pinpoint Test U .
Drive the vehicle and carry out a 4X2 mode to 4X4 mode
shift while driving at approximately 16 km/h (10 mph). No
Stop the vehicle, shift to 4X2 mode, drive the vehicle and GO to Q4 .
carry out a 4X2 mode to 4X4 mode shift while driving at
approximately 64 km/h (40 mph).
Does 4X4 mode engage correctly at 16 km/h (10 mph)
and at 64 km/h (40 mph)?
Q4 CHECK THE AVERAGE FRONT WHEEL SPEED
(FRT_WHL_SPD) AND AVERAGE REAR WHEEL SPEED
(REAR_WHL_SPD)
Yes
Enter the following diagnostic mode on the scan tool: GO to Q5 .
DataLogger - TCCM .
Monitor the FRT_WHL_SPD and REAR_WHL_SPD No
PIDs while driving in a straight line. REFER to Section 206-09 to
Do the FRT_WHL_SPD and REAR_WHL_SPD PIDs diagnose the wheel speed sensor
match? concern.

Q5 CHECK THE TRANSFER CASE CLUTCH LOCKUP

USING 4WD PWM CLUTCH STATUS (4WD CLTCH_OUT)
PID ACTIVE COMMAND
Yes
With the vehicle in NEUTRAL, position it on a hoist. GO to Q6 .
DataLogger - TCCM . GO to Q9 .
Switch the MSS to AUTO mode.
Using the 4WD CLTCH_OUT active command,
command the PID to 98%.
Rotate the rear driveshaft while observing the frt
driveshaft.
Does the front driveshaft rotate when the rear
driveshaft is rotated?
Q6 CHECK THE TRANSFER CASE CLUTCH RELEASE
USING 4WD PWM CLUTCH STATUS (4WD CLTCH_OUT)
PID ACTIVE COMMAND
Yes
With the vehicle still in NEUTRAL and on a hoist, using GO to Q15 .
the 4WD_CLTCH_OUT active command, command the
transfer case clutch to 0%. No
Rotate the rear driveshaft while observing the front End the active command. GO to Q7 .
driveshaft.
Does the front driveshaft rotate when the rear
driveshaft is rotated?
Q7 CHECK THE TRANSFER CASE ENGAGEMENT (ON
A HOIST)
Yes
Start the engine, switch the MSS to 4X2 mode. GO to Q8 .
Place the transmission in DRIVE and increase speed to
between 16 km/h (10 mph) and 24 km/h (15 mph). No
While observing the front driveshaft, switch the MSS to GO to Q15 .
4X4 mode.
Did the front driveshaft start to spin?
Q8 CHECK THE TRANSFER CASE DISENGAGEMENT
Yes
Switch the MSS to 4X2 mode while observing the front GO to Q15 .
driveshaft.
Does the front driveshaft rotate? No
Q9 CHECK CLUTCH CONTROL CIRCUIT FOR
VOLTAGE USING THE 4WD PWM CLUTCH STATUS
Yes
Using the 4WD_CLTCH_OUT active command, END the active command. INSTALL
command the transfer case clutch to 98%. a new transfer case synchronization
Measure the voltage by carefully back-probing transfer clutch. REFER to Section 308-07B .
case C350-16, circuit CCF03 (GY/BN), component side CLEAR the DTCs. TEST the system
and the transfer case housing. for normal operation.
No
PINPOINT TEST Q: 4WD DOES NOT ENGAGE AT SPEED CORRECTLY 2922

GO to Q10 .

Q10 CHECK THE TRANSFER CASE-TO-CHASSIS
GROUND USING THE 4WD PWM CLUTCH STATUS
Yes
Using the 4WD_CLTCH_OUT active command, END the active command. REPAIR
command the transfer case clutch to 98%. the transfer case ground connection
Measure the voltage by carefully back-probing transfer between the transfer case and the
case C350-16, circuit CCF03 (GY/BN), component side chassis. CLEAR the DTCs. TEST the
and chassis ground. system for normal operation.
No
GO to Q11 .

Q11 CHECK CLUTCH CONTROL CIRCUIT FOR A
SHORT TO GROUND
Yes
Ignition OFF. GO to Q12 .
Disconnect: TCCM C2371B. No
Measure the resistance between transfer case C350-16, REPAIR circuit CCF03 (GY/BN).
circuit CCF03 (GY/BN), harness side and ground. CLEAR the DTCs. TEST the system

Q12 CHECK CLUTCH CONTROL CIRCUIT FOR AN
OPEN

Ignition OFF. Yes

Disconnect: Transfer Case C350 (if not previously GO to Q13 .
disconnected).
Disconnect: TCCM C2371B (if not previously No
disconnected). REPAIR circuit CCF03 (GY/BN).
Measure the resistance between transfer case C350-16, CLEAR the DTCs. TEST the system
circuit CCF03 (GY/BN), harness side and TCCM for normal operation.
C2371B-1, circuit CCF03 (GY/BN), harness side.

Q13 CHECK CLUTCH CONTROL CIRCUIT FOR
VOLTAGE USING THE 4WD PWM CLUTCH STATUS
(4WD_CLTCH_OUT) PID ACTIVE COMMAND
Yes
Connect: Transfer Case C350. END the active command. GO to
Connect: TCCM C2371B. Q14 .
Ignition ON.
DataLogger - TCCM . END the active command. INSTALL
Using the 4WD_CLTCH_OUT active command, a new transfer case synchronization
command the transfer case clutch to greater than 10%. clutch. REFER to Section 308-07B .
Measure the voltage by carefully back-probing transfer CLEAR the DTCs. TEST the system
case C350-16, circuit CCF03 (GY/BN), component side for normal operation.
and ground.

Q14 CHECK CLUTCH CONTROL CIRCUIT FOR A
SHORT TO VOLTAGE USING THE 4WD PWM CLUTCH
Yes
Enter the following diagnostic mode on the scan tool: REPAIR circuit CCF03 (GY/BN).
DataLogger - TCCM . CLEAR the DTCs. TEST the system
Using the 4WD_CLTCH_OUT active command, for normal operation.
command the transfer case clutch to 0%.
Measure the voltage by carefully back-probing transfer No
case C350-16, circuit CCF03 (GY/BN), component side GO to Q15 .

and ground.

Q15 CHECK FOR CORRECT TCCM OPERATION
Yes
Check for: CLEAR the DTCs. TEST the system
damaged pins
pushed-out pins No
Connect all TCCM connectors and make sure they are The system is operating correctly at
seated correctly. this time. Concern may have been
Is the concern still present? connector. ADDRESS the root cause
of connector or pin issue.
Pinpoint Test R: The Four-Wheel Drive (4WD) System Jumps Out of Gear
Normal Operation
When the 4WD system engages the user selected mode, that mode should be maintained. If the 4WD system
does not stay in the selected mode, systematically check the 4WD system components.

Integrated Wheel End (IWE) vent line(s)
Transfer case
PINPOINT TEST R: THE 4WD SYSTEM JUMPS OUT OF GEAR

R1 CHECK FOR OBSTRUCTED IWE
VENT LINES
Yes
With the vehicle in NEUTRAL, INSTALL new IWE vent lines as necessary. TEST the
position it on a hoist. Refer to system for normal operation.
Section 100-02 .
NOTE: The IWE vent port is the No
smaller of the 2 vacuum ports. GO to R2 .
Disconnect the LH IWE line from
the vent port.

Attach a hand vacuum pump to the

IWE vent line.
Attempt to draw and hold a vacuum.
Connect the LH IWE line.
Disconnect the RH IWE line from
the vent port.
Attempt to draw and hold a vacuum.
Can a vacuum be held on either
IWE vent line?
R2 CHECK THE 4WD SWITCH
POSITION (4X4_SW) PID
Yes
Ignition ON. GO to R3 .
on the scan tool: DataLogger - No
TCCM . GO to Pinpoint Test N .
Drive the vehicle.
Monitor the 4X4_SW PID while
driving the vehicle in each MSS
position.

2H 2WD
4A Automatic
4H 4WD-HIGH
4L 4WD-LOW
Does the PID always agree with the

MSS position?
R3 CHECK THE 4WD INDICATORS
Yes
Stop the vehicle. GO to Pinpoint Test N .
Shift the transmission into the
NEUTRAL position. No
NOTE: 2H is indicated by the GO to R4 .
absence of 4X4 AUTO, 4H or 4L
mode indicators in the Instrument
Cluster (IC) message center.
Observe the 4WD indicators in the
Instrument Cluster (IC) while cycling
through each MSS position.
Do the 4WD indicators match MSS
switch positions?
R4 CHECK FOR TCCM DTCs
Yes
Shift the transmission into the PARK REFER to the Transfer Case Control Module (TCCM)
position. DTC Chart in this section for diagnosis.
on the scan tool: Self-Test - TCCM . No
PINPOINT TEST R: THE 4WD SYSTEM JUMPS OUT OF GEAR 2926

Are DTCs present? CHECK the transfer case fluid level. REFER to Section
308-07B . If the fluid level is OK, CHECK for internal
transfer case faults. REFER to Section 308-07B . TEST
Pinpoint Test S: Vehicle Pulsates or Shudders in a Straight Line (Straightline Driveline Wind-up)
Normal Operation
In order for the Four-Wheel Drive (4WD) system to function correctly, tires and wheels must be the same
size, be in good condition and the front and rear axle ratios must match.

PINPOINT TEST S: VEHICLE PULSATES OR SHUDDERS IN A STRAIGHT LINE (STRAIGHTLINE DRIVELINE

WIND-UP)
NOTE: 4X4 is not intended for driving on hard/dry surfaces; using 4X4 mode while driving on these surfaces
may produce noises like intermittent clunking, but will not damage driveline components.

S1 VERIFY THE CONCERN
Yes
Drive the vehicle and shift from 2H mode to 4H GO to S2 .
mode. There should be minimal wind-up in 4H
mode during straightline maneuvers (wind-up in No
turns is normal; 4H/4L is not intended for driving on RETURN the vehicle to the customer.
hard/dry surfaces). ADVISE about correct 4WD system
Is excessive wind-up present? operation and normal vehicle behavior.
S2 CHECK FOR MATCHING WHEEL AND TIRE
SIZES
Yes
Check the wheel and tire sizes. GO to S3 .
Do the 4 wheel and tire sizes match?
No
ADVISE the customer that 4WD systems
require 4 matched, correctly inflated,
correctly maintained tires to operate
correctly.
S3 CHECK TIRE WEAR
Yes
Check each of the 4 tires for wear. GO to S4 .
Are the 4 tires worn evenly?
No

correctly rotated tires to operate correctly.

S4 CHECK TIRE INFLATION PRESSURE
Yes
Check the inflation pressure in each tire. Refer to GO to S5 .
the Safety Certification Label on driver door or door
pillar. No
Are the tire inflation pressures correct? ADJUST the tire pressure as necessary.
TEST the vehicle for normal operation.
correctly maintained tires to operate
correctly.
S5 CHECK THE FRONT AND REAR AXLE RATIOS
Yes
Check that front and rear axle ratios match. Refer to RETURN the vehicle to the customer and
Section 205-00 . ADVISE about correct 4WD system usage
Do the front and rear axle ratios match? and normal vehicle behavior.
No
CHECK the Vehicle Certification (VC)
label. INSTALL the correct axle(s).
REFER to Section 205-02 or Section
205-03 . TEST the system for normal
operation.
Pinpoint Test T: The Front Axle Makes Noise in 2H Mode Only and Generally Under Heavy Throttle
Normal Operation
In 4X2 mode, the Transfer Case Control Module (TCCM) provides a ground path to the Integrated Wheel End
(IWE) solenoid to supply vacuum to each IWE (disengaging the front hubs from the front axle). During
certain conditions such as Wide Open Throttle (WOT) maneuvers, manifold vacuum is lower than desired. To
maintain uninterrupted IWE function in 4X2, stored engine vacuum is sourced from the vacuum reservoir. A
one-way check valve is implemented between the vacuum reservoir and the IWE solenoid to prevent the
stored vacuum from escaping into the manifold during low engine vacuum conditions. For noise-free IWE
operation under all conditions, the check valve must be operating correctly.

Vacuum leaks
Vacuum check valve
Vacuum reservoir
IWE solenoid
IWE
PINPOINT TEST T: THE FRONT AXLE MAKES NOISE IN 2H MODE ONLY AND GENERALLY UNDER HEAVY
THROTTLE
PINPOINT TEST S: VEHICLE PULSATES OR SHUDDERS IN A STRAIGHT LINE (STRAIGHTLINE

2928 DRIVE
T1 CHECK FOR GRINDING NOISES AT HIGH SPEEDS

Yes
WARNING: When directed to drive the vehicle as GO to T2 .
part of this test, drive the vehicle on a hard surface in
an area without traffic to prevent a crash. Failure to No
follow these instructions may result in personal IDENTIFY the customer concern and
injury. GO to the Symptom Charts in this
section.
With the vehicle warm and the MSS in 2H mode, drive
the vehicle at sustained WOT for 5 seconds.
Is there a grinding noise from the axle system during
WOT ?
T2 CHECK THE IWE SOLENOID OUTPUT VACUUM IN
2H
Yes
NOTE: The engine must be idling during the following GO to T7 .
steps to supply vacuum to the IWE solenoid.
Disconnect the output vacuum line at the IWE solenoid GO to T3 .
while having the vacuum supply attached to the solenoid.
With the engine running and the MSS in 2H mode,
measure the vacuum at the output port of the IWE
solenoid.
T3 CHECK THE IWE SOLENOID INPUT VACUUM
Yes
Disconnect the supply vacuum line at the IWE solenoid. INSTALL a new IWE solenoid.
With the engine still running, measure the supply line TEST the system for normal
vacuum to the IWE solenoid. operation.
No
GO to T4 .
T4 CHECK SOURCE VACUUM TO THE VACUUM
RESERVOIR
Yes
Disconnect the source vacuum line from the vacuum GO to T5 .
reservoir.
With the engine still running, measure the source vacuum No
being supplied to the vacuum reservoir. REPAIR or INSTALL a new source
Is the vacuum greater than 254 mm (10 in) Hg? vacuum line. TEST the system for
normal operation.
T5 CHECK THE VACUUM RESERVOIR
Yes
Disconnect the vacuum line from the vacuum reservoir.
Connect a hand vacuum pump to the source vacuum port No
on the vacuum reservoir and apply 508 mm (20 in) Hg of INSTALL a new vacuum reservoir.
vacuum. TEST the system for normal
Does the vacuum maintain or drop less than 25 mm (1 operation.
in) Hg per minute?
T6 CHECK THE ONE-WAY VACUUM CHECK VALVE
PINPOINT TEST T: THE FRONT AXLE MAKES NOISE IN 2H MODE ONLY AND GENERALLY2929
UNDER HE
NOTE: The check valve is between the IWE solenoid Yes

and the vacuum reservoir. Concern not present at this time.
Connect the vacuum lines to the IWE solenoid. CARRY OUT the Four-Wheel Drive
Connect a hand vacuum pump to the IWE solenoid (4WD) System Functional Test. GO
vacuum line at the vacuum reservoir and apply 508 mm to Pinpoint Test U .
(20 in) Hg of vacuum.
Does the vacuum maintain or drop less than 25 mm (1 No
in) Hg per minute? REPAIR or INSTALL new vacuum
lines or INSTALL a new one-way
check valve. TEST the system for
normal operation.
T7 CHECK THE IWE VACUUM SYSTEM
Yes
Ignition OFF. CONNECT the vacuum lines to the
Disconnect both vacuum lines from the IWE solenoid. IWE solenoid. GO to T11 .
Using a hand vacuum pump, apply 508 mm (20 in) Hg of
vacuum to the IWE system through the apply vacuum No
circuit. GO to T8 .
Observe the vacuum reading.
Does the vacuum maintain or drop less than 25 mm (1
in) Hg per minute?
T8 CHECK THE RH IWE LEAK RATE
Yes
With the vehicle in NEUTRAL, position it on a hoist. GO to T9 .
Disconnect the vacuum line from the larger port on the No
RH IWE . INSTALL a new RH IWE . REFER
Apply 508 mm (20 in) Hg of vacuum to the RH IWE port to Integrated Wheel End (IWE) in this
and observe vacuum reading. section. TEST the system for normal
Does the vacuum maintain or drop less than 25 mm (1 operation.
in) Hg per minute?
T9 CHECK THE LH IWE LEAK RATE
Yes
Disconnect the vacuum line from the larger port at the GO to T10 .
LH IWE .
Apply 508 mm (20 in) Hg of vacuum to the LH IWE port No
and observe vacuum reading. INSTALL a new LH IWE . REFER to
Does the vacuum maintain or drop less than 25 mm (1 Integrated Wheel End (IWE) in this
in) Hg per minute? section. TEST the system for normal
operation.
T10 CHECK THE IWE VACUUM SUPPLY TUBE
Yes
Disconnect both vacuum lines from the IWE solenoid. GO to T11 .
Plug both LH and RH IWE vacuum lines. Apply 508 mm
(20 in) Hg of vacuum to the IWE apply vacuum circuit No
and observe the vacuum reading. INSTALL new vacuum lines as
Does the vacuum maintain or drop less than 25 mm (1 necessary. TEST the system for
in) Hg per minute? normal operation.
T11 CHECK THE IWE VACUUM SUPPLY AT EACH
IWE IN 2H
Yes
GO to T12 .
UNDER HE
Connect a hand-held vacuum gauge to the LH IWE

vacuum supply tube. No
NOTE: The engine must be idling during the following INSTALL new vacuum lines as
steps to supply the vacuum required for the IWE to necessary. TEST the system for
engage and disengage. normal operation.
Start the engine.
Switch the MSS to 2H mode while observing the vacuum
gauge.
Repeat these steps for the RH IWE .
Are the vacuum readings greater than 254 mm (10 in)
Hg?
T12 CHECK THE LH IWE VACUUM LINE FOR AN
OBSTRUCTION
Yes
Ignition OFF. INSTALL a new vacuum line. TEST
Disconnect both vacuum lines from the IWE solenoid. the system for normal operation.
Refer to Section 100-02 . No
Disconnect the vacuum line at the LH IWE . CONNECT the vacuum line to the
Connect a hand vacuum pump to the LH IWE vacuum LH IWE . GO to T13 .
Did the hand vacuum pump draw a vacuum on the
LH IWE vacuum line?
T13 CHECK THE RH IWE VACUUM LINE FOR AN
OBSTRUCTION
Yes
Disconnect the larger vacuum line at the RH IWE . INSTALL a new vacuum line. TEST
Connect a hand vacuum pump to the RH IWE vacuum the system for normal operation.
Did the hand vacuum pump draw a vacuum on the No
RH IWE vacuum line? CONNECT the vacuum line to the
RH IWE . GO to T14 .
T14 CHECK THE LH IWE OPERATION
Yes
Connect a hand vacuum pump with gauge to the larger
port of the LH IWE . No
Observe the LH halfshaft while rotating the LH front tire. INSTALL a new LH IWE . REFER to
Apply between 152 and 203 mm (6 to 8 in) Hg of Integrated Wheel End (IWE) in this
vacuum and release the vacuum to manually disengage section. TEST the system for normal
and engage the LH IWE . operation.
Did the LH IWE disengage between 152 and 203 mm
(6 to 8 in) Hg and engage when the vacuum is
released?
T15 CHECK THE RH IWE OPERATION
Yes
Connect a hand vacuum pump with gauge to the larger GO to Pinpoint Test U .
port of the RH IWE .
Observe the RH halfshaft while rotating the RH front tire. No
Apply between 152 and 203 mm (6 to 8 in) Hg of INSTALL a new RH IWE . REFER
vacuum and release the vacuum to manually disengage to Integrated Wheel End (IWE) in this
and engage the RH IWE . section. TEST the system for normal
UNDER HE
Did the RH IWE disengage between 152 and 203 mm operation.

(6 to 8 in) Hg and engage when the vacuum is
released?
Pinpoint Test U: Four-Wheel Drive (4WD) System Functional Test
Normal Operation
When operating in 4WD , the transfer case and both Integrated Wheel Ends (IWEs) are locked. When in 4L
mode, the transfer case low range gear set provides an additional 2.64 gear reduction. When operating in 2H
mode, the transfer case and both IWEs are unlocked.

Transfer case and related components
IWEs and related components
Wheel/tire assemblies
PINPOINT TEST U: FOUR-WHEEL DRIVE (4WD) SYSTEM FUNCTIONAL TEST

U1 CHECK 2H MODE OPERATION
Yes
Shift the transmission into the NEUTRAL GO to U2 .
position.
Switch the Mode Select Switch (MSS) to No
2H mode. GO to U4 .
Are there any 4WD mode indicators
present in the Instrument Cluster (IC)
message center?
U2 CHECK FOR TCCM DTCs
Yes
Shift the transmission into the PARK REFER to the Transfer Case Control Module
position. (TCCM) DTC Chart in this section for diagnosis.
Ignition ON.
Enter the following diagnostic mode on the No
scan tool: Self-Test - TCCM . GO to U3 .
Are DTCs retrieved?
U3 CHECK FOR WIND-UP IN 2H MODE
Yes
Drive the vehicle on a dry, hard surface GO to Pinpoint Test P .
while executing turns.
U4 CHECK AUTO MODE OPERATION

Switch the MSS to 4A mode. Yes

Is the 4X4 auto (4A) mode indicator on GO to U7 .
in the IC message center?
No
GO to U5 .
U5 CHECK FOR DTCs
Yes
Ignition ON. REFER to the Transfer Case Control Module
Enter the following diagnostic mode on the (TCCM) DTC Chart in this section for diagnosis.
scan tool: Self-Test - TCCM .
Are DTCs present? No
GO to U6 .
U6 CHECK FOR WIND-UP IN 4A MODE
Yes
Drive the vehicle on a dry, hard surface, GO to U7 .
executing turns while applying the throttle.
GO to U8 .
U7 CHECK THE 4WD PWM CLUTCH
STATUS (4WD_CLTCH_OUT) PID
Yes
Enter the following diagnostic mode on the GO to U8 .
scan tool: DataLogger - TCCM .
Monitor the 4WD_CLTCH_OUT PID. No
Does the PID indicate 2 to 10% clutch GO to U9 .
application at closed throttle?
U8 CHECK FOR WIND-UP IN 4A MODE
WITH 100% CLUTCH USING THE 4WD
PWM CLUTCH STATUS
Yes
Command the 4WD_CLTCH_OUT to No
100%. CHECK the transfer case. REFER to Section
Drive the vehicle on a dhard surface, 308-07B .
executing turns.
Is wind-up present in turns?
U9 CHECK AVERAGE FRONT WHEEL
SPEED (FRT_WHL_SPD) AND AVERAGE
REAR WHEEL SPEED (REAR_WHL_SPD)
PIDs
Yes
Monitor the FRT_WHL_SPD and No
REAR_WHL_SPD PIDs. VERIFY all 4 tires are the same size and bra.
Drive the vehicle 30 km/h (18 mph). INSTALL new tires as necessary. If the tires are
Record and compare the FRT_WHL_SPD OK, CHECK the ABS. REFER to Section 206-09
and REAR_WHL_SPD PIDs. and VERIFY that the 4 road tire sizes match. TEST
Do the FRT_WHL_SPD and the system for normal operation.
REAR_WHL_SPD PID values match
PINPOINT TEST U: FOUR-WHEEL DRIVE (4WD) SYSTEM FUNCTIONAL TEST 2933

within 1.5 km/h (1 mph)?

U10 CHECK THE ABSOLUTE THROTTLE
Yes
Ignition ON. No
Monitor the TP_TCCM PID. CHECK the APP sensor and/or the PCM. REFER to
NOTE: The TP_TCCM PID is the Powertrain Control/Emissions Diagnosis
Accelerator Pedal Position (APP) as (PC/ED) manual.
communicated by the PCM via High Speed
Controller Area Network (HS-CAN).
Slowly move throttle from closed throttle
to Wide Open Throttle (WOT) and observe
the TP_TCCM PID.
Does the TP_TCCM PID value vary
between 0% at closed throttle and 100%
at WOT ?
U11 CHECK 4H MODE OPERATION
Yes
Switch the MSS to 4H mode. GO to U14 .
Does the 4X4 (4H) indicator illuminate
in the IC message center correctly? No
GO to U12 .
U12 CHECK FOR DTCs
Yes
Are DTCs retrieved?
Yes
Drive the vehicle on a dry, hard surface GO to Pinpoint Test Q .
U14 CHECK FOR STRAIGHTLINE
WIND-UP IN 4H MODE
Yes
Drive the vehicle on a dry, hard surface. GO to Pinpoint Test S .
Is straightline wind-up present?
No
GO to U15 .
U15 CHECK WIND-UP IN TURNS IN 4H
MODE
Yes
Drive the vehicle in 4H mode while GO to U16 .
turning.

U16 CHECK 4L MODE OPERATION

Yes
Bring the vehicle to a stop with the GO to U19 .
transmission in NEUTRAL, switch the
MSS to 4L mode. No
Does the 4WD LOW (4L) indicator in GO to U17 .
the IC message center illuminate
correctly?
U17 CHECK FOR DTCs
Yes
scan tool: Self-Test - TCCM . No
Are DTCs retrieved? GO to U18 .
U18 CHECK FOR WIND-UP IN 4L MODE
Yes
Drive the vehicle on a dry, hard surface GO to Pinpoint Test V .
Is wind-up prent in turns? No
GO to Pinpoint Test P .
U19 CHECK FOR WIND-UP IN TURNS IN
4L MODE
Yes
Drive the vehicle on a dry, hard surface GO to U20 .
Is wind-up present and 4L mode No
functioning? CHECK for TCCM DTCs. REFER to the Inspection
and Verification procedure in this section. If no
DTCs are present, GO to Pinpoint Test P .
U20 CHECK 4L MODE TO 2H MODE
SHIFT
Yes
With the vehicle at a stop and transmission GO to U21 .
in NEUTRAL, switch the MSS from 4L
mode to 2H mode. No
Are there any 4WD mode indicators GO to U23 .
present in the IC message center?
U21 CHECK FOR DTCs
Yes
Release the brake pedal.
Are DTCsetrieved?
Yes
Drive the vehicle on a dry, hard surface GO to Pinpoint Test P .

U23 CHECK FOR TRANSFER CASE
DISENGAGEMENT
Yes
With the vehicle in NEUTRAL, position it REFER to Section 308-07B .
on a hoist. Refer to Section 100-02 .
Rotate the rear driveshaft while observing No
the front driveshaft. GO to U24 .
Does the front driveshaft rotate?
U24 CHECK FOR LH AND RH IWE
DISENGAGEMENT
Yes
NOTE: The engine must be at idle during GO to Pinpoint Test N .
the following steps to supply vacuum for
IWE engagement/disengagement. No
GO to U25 .
Start the engine and allow to idle.
Rotate the LF tire one revolution forward
and one revolution backward while
observing the LF halfshaft and U-joint.
Rotate the RF tire one revolution forward
and one revolution backward while
observing the RF halfshaft and U-joint.
Does the LH or RH front halfshaft
rotate?
U25 CHECK FOR IWE VACUUM LEAKS
Yes
Ignition OFF. CHECK the IWE and related components for leaks.
Disconnect both vacuum lines from the GO to Pinpoint Test N .
IWE solenoid.
Using a hand vacuum pump, apply 508 No
mm (20 in) Hg of vacuum to the IWE GO to U26 .
apply vacuum circuit.
Observe the vacuum reading.
Did the vacuum drop more than 25 mm
(1 in) Hg per minute?
U26 CHECK 2H MODE TO 4H MODE
SHIFT AT SPEED ABOVE 32 KM/H (20
MPH)
Yes
Switch the MSS to 2H mode. The 4WD system is functioning correctly.
Drive the vehicle on the road and shift
from 2H mode to 4H mode while driving No
above 32 km/h (20 mph). GO to Pinpoint Test Q .
Does the transfer case shift to 4H mode
satisfactorily?
Pinpoint Test V: The 4X4 Mode Indicators Do Not Operate Correctly/Do Not Operate

Normal Operation
The Four-Wheel Drive (4WD) system status is transmitted to the Instrument Cluster (IC) from the Transfer
Case Control Module (TCCM) through the High Speed Controller Area Network (HS-CAN) to the powertrain
malfunction indicator. A steady indicator displays if the vehicle is in 4X4 auto (4A), 4X4 (4H) or 4X4 low
(4L). When in 2-Wheel Drive (2WD), the message center will display 4X2 for approximately 4 seconds, then
the message center will no longer provide 4WD system indication until another shift mode is attained. A
system fault condition will illuminate the powertrain malfunction indicator. The powertrain malfunction
indicator includes other general powertrain system failures. For information about HS-CAN , refer to Section
418-00 .

IC
4WD system fault
HS-CAN circuits
TCCM
PINPOINT TEST V: THE 4X4 MODE INDICATORS DO NOT OPERATE CORRECTLY/DO NOT OPERATE

V1 CHECK FOR TCCM DTCs
Yes
Ignition ON. REFER to the Transfer Case Control Module
Enter the following diagnostic mode on the (TCCM) DTC Chart in this section for diagnosis.
scan tool: Self-Test - TCCM .
Are DTCs present? No
GO to V2 .
V2 CHECK FOR IC DTCs
Yes
Ignition ON. REFER to Section 413-01 .
Enter t following diagnostic mode on the
scan tool: Self-Test - IC . No
Are DTCs present? GO to V3 .
V3 CHECK 4WD SYSTEM OPERATION
Yes
Test drive the vehicle and operate the 4WD REFER to Section 413-01 .
system.
Does the 4WD system operate correctly? No
GO to Symptom Chart - Four Wheel Drive (4WD)
in this section.
Pinpoint Test W: Vehicle Binds in a Turn/Resists Turning/Pulsates in a Straightline in 4WD Mode
Normal Operation
When the vehicle is operating in Four-Wheel Drive (4WD) (4H/4L modes), all 4 wheels receive the same
amount of torque and rotate at the same speed. The amount of traction the vehicle can achieve depends on the
amount of traction each tire can establish with the road surface. In order for the 4WD system to function
correctly, each tire must be in good condition and the front and rear axle ratios must match.

PINPOINT TEST W: VEHICLE BINDS IN A TURN/RESISTS TURNING/PULSATES IN A STRAIGHTLINE IN 4WD

MODE

W1 VERIFY THE CONCERN
Yes
Test drive the vehicle on a straight If the problem occurs in 4A mode, GO to W2 ; If 4H
stretch of road in 4A mode. mode or 4L mode, binding is a normal condition.
Drive the vehicle through turns and
parking lot maneuvers. No
Does the vehicle bind, pulsate or GO to Pinpoint Test S .
shudder?
W2 CHECK THE 4H AND 4L
INDICATORS
Yes
Review the test drive notes. If the powertrain malfunction indicator (wrench light)
Did the 4X4 (4H) or 4X4 LOW (4L) or illuminated, GO to W4 .
powertrain malfunction indicator
(wrench light) illuminate in the If the 4H mode or 4L mode indicators illuminated, GO
Instrument Cluster (IC) message to W3 .
center?
No
GO to W5 .
W3 VERIFY THE FAULT
Yes
Review the test drive notes. The system is functioning correctly.
Was 4H mode or 4L mode selected
when the 4H or 4L indicators were No
illuminated in the IC message center? The fault may have been caused by an intermittent,
uncommanded or autolock shift. TEST the system for
normal operation. GO to Pinpoint Test S .
W4 CHECK FOR DTCs
Yes
Enter the following diagnostic mode on REFER to the Transfer Case Control Module (TCCM)
the scan tool: Self-Test - TCCM . DTC Chart for diagnosis.
Are DTCs retrieved?
No
GO to W5 .
W5 VERIFY THE CONCERN
Yes
Disconnect: Transfer Case C350. INSPECT the driveline components for damage or

Test drive the vehicle on a straight wear. REFER to Inspection and Verification in this
stretch of road and in turns, and shift the section. TEST the system for normal operation.
transfer case through each mode. Record
any fault conditions. No
Is the concern present? GO to W6 .
W6 CHECK THE 4WD PWM CLUTCH
STATUS (4WD_CLTCH_OUT) PI
Yes
Connect: Transfer Case C350. GO to W7 .
Using the scan tool, clear the DTCs.
the scan tool: DataLogger - TCCM . CHECK the transfer case. REFER to Section 308-07B
Monitor the 4WD_CLTCH_OUT PID at . TEST the system for normal operation.
closed throttle, Key ON Engine OFF
(KOEO).
Select 4H mode.
Does the PID indicate 2 to 10% clutch
application at closed throttle?
W7 CHECK THE ABS MODULE WHEEL
SPEED SENSOR PIDs
Yes
Enter the following diagnostic mode on GO to W8 .
the scan tool: DataLogger - ABS
Module. No
While driving the vehicle at 30 km/h (18 VERIFY that the 4 road wheels are the same size and
mph), monitor the following wheel have similar tread depth. CHECK the ABS for faults.
speed sensor PIDs: REFER to Section 206-09 . TEST the system for
Left Front Wheel Speed Sensor normal operation.
(LF_WSPD)
Left Rear Wheel Speed Sensor
(LR_WSPD)
(RF_WSPD)
(RR_WSPD)
Compare speedometer reading to the
wheel speed sensor PIDs.
Do the wheel speed sensor PIDs and
speedometer speeds match within 1.5
km/h (1 mph)?
W8 CHECK THE ABSOLUTE
THROTTLE POSITION (TP_TCCM) PID
Yes GO to W9 .
the scan tool: DataLogger - TCCM . No
NOTE: The TP_TCCM PID is DIAGNOSE the PCM. REFER to the Powertrain
Accelerator Pedal Position (APP) as Control/Emissions Diagnosis (PC/ED) manual.
communicated by the PCM via High TEST the system for normal operation.
Speed Controller Area Network
(HS-CAN).
Slowly move accelerator pedal from
closed throttle to Wide Open Throttle
(WOT) and observe the TP_TCCM PID.
PINPOINT TEST W: VEHICLE BINDS IN A TURN/RESISTS TURNING/PULSATES IN A STRAIGHTLINE

2939 IN
Does the TP_TCCM PID value vary

between 0% at closed throttle and
100% at WOT ?
W9 CHECK THE TRANSFER CASE
FRONT DRIVESHAFT OUTPUT
Yes
With the vehicle in NEUTRAL, position GO to W10 .
it on a hoist. Refer to Section 100-02 .
Rotate the front driveshaft by hand. No
Does the front driveshaft rotate freely CHECK the transfer case. REFER to Section 308-07B
(does it require less than 45 Nm [33 . TEST the system for normal operation.
lb-ft] to rotate)?
W10 CHECK FOR CORRECT TCCM
OPERATION
Yes
Ignition OFF. INSTALL a new TCCM . REFER to 4X4 Control
Disconnect all TCCM connectors. Module in this section. TEST the system for normal
Check for: operation.
corrosion.
damaged pins No
pushed-out pins. The system is operating correctly at this time. Concern
Connect all TCCM connectors and make may have been caused by a loose or corroded
sure they are seated correctly. connector. ADDRESS the root cause of the connector
Operate the system and verify the concern. TEST the system for normal operation.
Pinpoint Test X: The Vehicle Does Not Shift Between 2H (2WD) and 4X4 Modes Correctly
Normal Operation
The Mode Select Switch (MSS) communicates the operator's choice to the Transfer Case Control Module
(TCCM). The TCCM then controls the transfer case synchronization clutch, transfer case motor and
Integrated Wheel Ends (IWEs) as necessary. If the vehicle is not responding as intended, systematically check
the necessary inputs and outputs of the TCCM , components of the transfer case, IWE components and
halfshafts. Check all circuits for opens and shorts to power or ground.

Fault sets when TCCM C2371A pin 16 senses an open circuit. Four-Wheel
P1812:00 - 4-Wheel Drive (4WD) system mode cannot be changed.
Drive Mode Select
Circuit Failure: No
Sub Type Information
Fault sets when TCCM C2371A pin 16 detects a short to ground. 4WD
P1815:00 - 4-Wheel system mode cannot be changed.
Drive Mode Select
Short To Ground: No

Sub Type Information

Fault sets when TCCM C2371B pin 4 or 5 detects an open circuit. Shift
P1839:00 - Transfer motor moves are prevented when this DTC is set.
Case Shift Motor
Open Circuit: No Sub
Type Information
Fault sets when TCCM C2371B pin 4 or 5 detects a short to voltage. Shift
P1840:00 - Transfer motor moves are prevented when this DTC is set.
Case Shift Motor
Short Circuit To
Battery: No Sub Type
Information
Fault sets when TCCM C2371B pin 4 octs a short to ground. Shift motor
P1841:00 - Transfer moves are prevented when this DTC is set.
Case Shift Motor
Short Circuit To
Ground: No Sub Type
Information
Fault sets when TCCM C2371A pin 1 detects a short to ground. Shift motor
P1849:00 - Transfer moves are prevented when this DTC is set. The TCCM will not complete
Case Contact Plate 'A' mode change if a change in shift motor position is required.
Short Circuit To
Ground: No Sub Type
Information
Case Contact Plate 'B' mode change if a change in shift motor position is required.
Short Circuit to
Ground: No Sub Type
Information
Case Contact Plate 'C' mode change if a change in shift motor position is required.
Short Circuit to
Ground: No Sub Type
Information
Case Contact Plate 'D' mode change if a change in shift motor position is required.
Short Circuit to
Ground: No Sub Type
Information
Fault sets when an invalid shift motor position is detected during selection of
P1867:00 - Transfer a new 4WD mode or during a motor movement. If the shift motor is not
Case Contact Plate moving, shift motor movement will be prevented. If the shift motor is
General Circuit moving when this DTC sets, the shift motor will move to the high-side
Failure: No Sub Type mechanical stop.
Information
Fault sets when TCCM C2371A pin 5 detects a short to ground, a short to
P1891:00 - Transfer voltage or open circuit. The TCCM will not complete mode change if a
Case Contact Plate change in shift motor position is required.
Ground Return Open

Circuit: No Sub Type

Information

MSS
Transfer case
IWEs
IWE solenoid
TCCM
Front axle assembly
PINPOINT TEST X: THE VEHICLE DOES NOT SHIFT BETWEEN 2H (2WD) AND 4X4 MODES CORRECTLY
WARNING: When directed to drive the vehicle as part of this test, drive the vehicle on a hard
surface in an area without traffic to prevent a crash. Failure to follow these instructions may result in
personal injury.

X1 CHECK FOR TCCM DTCs
Yes
Ignition ON. For DTC P1812:00, GO to X5 .
Self-Test - TCCM . For DTC P1815:00, GO to X7 .
For DTC P1839:00, GO to X25 .

Transfer Case Control Module
(TCCM) DTC Chart in this section.
No
GO to X2 .
X2 CHECK THE TCCM IGNITION POSITION
PINPOINT TEST X: THE VEHICLE DOES NOT SHIFT BETWEEN 2H (2WD) AND 4X4 MODES
2942
CORRECT
(KEY_POS_4X4) AND IGNITION STATUS

(KEY_STATUS_4X4) PIDs
Yes
Enter the following diagnostic mode on the scan tool: GO to X3 .
DataLogger - TCCM .
Monitor the KEY_POS_4X4 and KEY_STATUS_4X4 No
PIDs while cycling through each position. If the KEY_STATUS_4X4 PID did
Do the ignition PIDs match the ignition switch not match, CHECK SJB fuse 35
positions? (10A If the fuse is OK, REPAIR
circuit CBP35 (YE/GY). If the fuse
is not OK, REFER to the Wiring
operation.
If the KEY_POS_4X4 PID did not

match, REFER to Section 211-05 to
diagnose the ignition switch concern.
operation.
X3 CHECK THE TCCM MODULE SUPPLY VOLTAGE
(VBAT_4X4) PID
Yes
Ignition ON. GO to X4 .
DataLogger - TCCM . No
Start the engine and monitor the VBAT_4X4 PID. REFER to Section 414-00 to
Is the VBAT_4X4 PID greater than 12 volts? DIAGNOSE the low battery voltage
and/or charging system concern.
CLEAR the DTCs. TEST the system
X4 CHECK THE MSS POSITION MONITORING THE
TCCM 4WD SWITCH STATUS (4X4_SW) PID
Yes
DataLogger - TCCM .
Monitor the 4X4_SW PID while switching to each MSS No
position. GO to X5 .

2H 2WD
4A Automatic
4H 4WD-HIGH
4L 4WD-LOW
X5 CHECK THE MSS RESISTANCE VALUES
2943
CORRECT
Ignition OFF. Yes

Disconnect: MSS C284. GO to X6 .
Measure the resistance between MSS C284 pins 2 and 3,
component side, while rotating the MSS through all No
positions. Refer to the following chart. INSTALL a new MSS . CLEAR the
DTCs. TEST the system for normal
operation.
MSS Position Resistance (1%)

2H 619 ohms
4A 270 ohms
4H 130 ohms
4L 62 ohms

X6 CHECK THE MSS CONTROL AND RETURN
Yes
Disconnect: TCCM C2371A. REPAIR the affected circuit(s).
Ignition ON. CLEAR the DTCs. TEST the system
Measure the voltage between MSS C284-3, circuit RCF13 for normal operation.
(WH/BN), harness side and ground; and between MSS
C284-2, circuit CCF13 (WH/BU), harness side and No
ground. GO to X7 .

CIRCUITS FOR SHORT TO GROUND
Yes
Ignition OFF. GO to X8 .
Disconnect: TCCM C2371A.
Disconnect: MSS C284. No
Measure the resistance between MSS C284-3, circuit REPAIR the affected circuit(s).
RCF13 (WH/BN), harness side and ground; and between CLEAR the DTCs. TEST the system
2944
CORRECT
MSS C284-2, circuit CCF13 (WH/BU), harness side and for normal operation.
ground.

Yes
Measure the resistance between MSS C284, and TCCM GO to X9 .
C2371A, harness side. Refer to the following chart.
No
MSS Circuit TCCM
C284-3 RCF13 (WH/BN) C2371A-14
C284-2 CCF13 (WH/BU) C2371A-16

Yes
Measure the resistance between MSS C284-3, circuit REPAIR the affected circuit(s).
RCF13 (WH/BN), harness side and MSS C284-2, circuit CLEAR the DTCs.
CCF13 (WH/BU), harness side.
2945
CORRECT

X10 CHECK THE AVERAGE FRONT WHEEL SPEED
(FRT_WHL_SPD) AND AVERAGE REAR WHEEL SPEED
(REAR_WHL_SPD) PIDs
Yes
Connect: TCCM C2371A.
Connect: MSS C284. No
Ignition ON. REFER to Section 206-09 to
Switch the MSS to 2H. diagnose the wheel speed concern.
Enter the following diagnostic mode on the scan tool: After the repair is complete, CLEAR
DataLogger - TCCM . the DTCs. TEST the system for
Monitor the FRT_WHL_SPD and REAR_WHL_SPD normal operation.
PIDs with the vehicle stopped and while driving.
Do the FRT_WHL_SPD and REAR_WHL_SPD PIDs
match with the vehicle stopped and at all speeds?
X11 CHECK 4WD MODES (4WD_MODES) WITH THE
MSS IN 4H
Yes
Start the engine. GO to X14 .
Switch the MSS to 4H.
Monitor the 4WD_MODES PID. No
Does the 4WD_MODES PID indicate 4WD High? GO to X12 .
X12 CHECK FOR 4H WIND-UP
Yes
Switch the MSS to 4H. GO to X15 .
Drive the vehicle on a dry, hard surface in turns.
GO to X13 .
X13 CHECK FOR TRANSFER CASE ENGAGEMENT
Yes
With the vehicle in NEUTRAL, position it on a hoist. GO to X14 .
Rotate the rear driveshaft. No
Observe the front driveshaft. GO to X18 .
Did the front driveshaft rotate?
X14 CHECK FOR IWE ENGAGEMENT
Yes
With the vehicle in NEUTRAL, position it on a hoist. CHECK that all driveline fasteners
Refer to Section 100-02 . are present and tightened to
NOTE: The engine must be idling during the following specification. REFER to Section
steps to supply the vacuum required for the IWEs to 205-00 for further diagnosis of the
engage and disengage. front axle.
Start the engine.
No
2946
CORRECT
Rotate the LH front tire one revolution forward and one GO to Pinpoint Test N .
revolution backward while observing the LH front
halfshaft and U-joint.
Rotate the RH front tire one revolution forward and one
revolution backward while observing the RH front
Did both front halfshafts rotate?
X15 CHECK THE TRANSFER CASE SHIFT TO 2H
Yes
Ignition ON. GO to X16 .
DataLogger - TCCM . No
Command the Transfer Case Shift Motor Position Sense GO to X19 .
Contact Plate Power (PLATE_PWR_OS) PID to energize
the transfer case gearmotor encoder assembly.
Monitor the Transfer Case Contact Plate Switch A
(PLATE_A), B (PLATE_B), C (PLATE_C) and D
(PLATE_D) PIDs for the contact plate position with the
MSS in the 2H position.
MSS Contact Plate Position

Position PLATE_A PLATE_B PLATE_C PLATE_D
2H/4A/4H CLOSED OPEN CLOSED CLOSED
Mode
4L Mode OPEN CLOSED OPEN CLOSED
Do the PIDs and message center indicate that vehicle

shifted into 2H (4X2 displayed in message center for
approximately 4 seconds)?
X16 CHECK FOR IWE DISENGAGEMENT
Yes
With the vehicle in NEUTRAL, position it on a hoist. GO to Pinpoint Test N .
Rotate the LH front tire one revolution forward and one No
revolution backward while observing the LH front GO to X17 .
Rotate the RH front tire one revolution forward and one
revolution backward while observing the RH front
Did either of the front halfshafts rotate?
X17 CHECK FOR TRANSFER CASE DISENGAGEMENT
Yes
Rotate the rear driveshaft while observing the front The system is functioning correctly.
driveshaft. CARRY OUT the Four-Wheel Drive
Does the front driveshaft rotate? (4WD) Functional Test. GO to
Pinpoint Test u .
No
GO to X18 .
2947
CORRECT
X18 CHECK THE TRANSFER CASE CONTACT PLATE

POSITION PIDs
Yes
DataLogger - TCCM .
Command the Transfer Case Shift Motor Position Sense No
Contact Plate Power (PLATE_PWR_OS) PID to energize GO to X19 .
the transfer case gearmotor encoder assembly.
Monitor the Transfer Case Contact Plate Switch A
(PLATE_A), B (PLATE_B), C (PLATE C) and D
(PLATE_D) PIDs for the contact plate position with the
MSS in the 4H position.
MSS Contact Plate Position

Position PLATE_A PLATE_B PLATE_C PLATE_D
2H/4A/4H CLOSED OPEN CLOSED CLOSED
Mode
4L Mode OPEN CLOSED OPEN CLOSED
Did the PIDs and message center indicate that the

vehicle shifted into 4H (4X4 HIGH)?
X19 CHECK THE TRANSFER CASE SHIFT MOTOR
OPERATION
Yes
Remove the transfer case shift motor from the transfer GO to X29 .
case, leaving the wiring connector connected.
Observe the transfer case shift motor while switching the No
MSS from 2H to 4H. GO to X20 .
Does the transfer case shift motor rotate from the 2H
position to the 4H position?
X20 CHECK TRANSFER PLATE CONTACT PLATE
Yes
Ignition ON. REPAIR the affected circuit(s).
Measure the voltage between the following circuits at CLEAR the DTCs. TEST the system
TCCM C2371A, harness side and ground: for normal operation.
No
GO to X21 .
Circuit C2371A Pin

CCF14 (WH) 1
CCF15 (BN/YE) 2
CCF16 (VT/GN) 3
CCF17 (WH/OG) 4
RCF09 (BN/WH) 5
2948
CORRECT

X21 CHECK TRANSFER PLATE CONTACT PLATE
Yes
Disconnect: Transfer Case C350 (if not previously
disconnected). No
Disconnect: TCCM C2371A (if not previously REPAIR the affected circuit(s).
disconnected). CLEAR the DTCs. TEST the system
Measure the resistance between the following circuits at for normal operation.
TCCM C2371A, harness side and ground:
Circuit C2371A Pin

CCF14 (WH) 1
CCF15 (BN/YE) 2
CCF16 (VT/GN) 3
CCF17 (WH/OG) 4
RCF09 (BN/WH) 5

X22 CHECK THE TRANSFER PLATE CONTACT PLATE
Yes
Measure the resistance of the following circuits between REPAIR the affected circuit(s).
TCCM C2371A, harness side and transfer case C350, CLEAR the DTCs. TEST the system
harness side: for normal operation.
2949
CORRECT
Circuit C2371A Pin C350 Pin

CCF14 (GN/OG) 1 5
CCF15 (BN/YE) 2 1
CCF16 (VT/GN) 3 9
CCF17 (WH/OG) 4 13
RCF09 (BN/WH) 5 10

X23 CHECK THE SHIFT MOTOR FOR AN INTERNAL
SHORT TO GROUND
Yes
Measure the resistance between transfer case C350 pins 1, GO to X24 .
5, 9, 10 and 13, component side and ground.
No
INSTALL a new transfer case shift
motor. CLEAR the DTCs. REPEAT
the self-test. If the concern is still
present, GO to X30 .

X24 CHECK THE SHIFT MOTOR CIRCUITS FOR
POWER WHILE COMMANDING THE CW RELAY
(CW_SMD_OS) AND CCW RELAY (CCW_SMD_OS) PIDs
ON
Yes
Connect: TCCM C2371A. GO to X29 .
Ignition ON.
DataLogger - TCCM . GO to X25 .
Command the CW_SMD_OS PID ON and OFF while
measuring the voltage between transfer case C350-14,
circuit CCF08 (GY/OG), harness side and ground. Then
command the CCW_SMD_OS PID ON and OFF while
measuring the voltage between transfer case C350-15,
circuit CCF07 (BN/GN), harness side and ground.
2950
CORRECT
Are the voltages 9 volts or greater on the circuits when

commanding the PIDs ON?
X25 CHECK THE TCCM VOLTAGE CIRCUIT
Yes
Measure the voltage between TCCM C2371B-6, circuit No
SBB20 (GN/RD), harness side and ground. VERIFY BJB fuse 20 (20A) is OK.
If OK, REPAIR circuit SBB20
(BN/RD). If not OK, REFER to the
Wiring Diagrams manual to identify

Yes
Disconnect: Transfer Case C350. No
Measure the resistance between transfer case C350, REPAIR the affected circuit(s).
harness side and TCCM C2371B, harness side. Refer to CLEAR the DTCs. TEST the system
the following chart. for normal operation.
Transfer Case Circuit TCCM

C350-14 CCF08 (GY/OG) C2371B-5
C350-15 CCF07 (BN/GN) C2371B-4
2951
CORRECT

Yes
Ignition OFF. REPAIR the affected circuit(s).
Disconnect: TCCM C2371B (if not previously CLEAR the DTCs. TEST the system
disconnected). for normal operation.
Disconnect: Transfer Case C350 (if not previously
disconnected). No
Measure the voltage between transfer case C350-14, GO to X28 .
circuit CCF08 (GY/OG), harness side and ground; and
between transfer case C350-15, circuit CCF07 (BN/GN),

CIRCUITS FOR SHORT TO GROUND
Yes
Disconnect: TCCM C2371B (if not previously
disconnected). No
Disconnect: Transfer Case C350 (if not previously REPAIR the affected circuit(s).
disconnected). CLEAR the DTCs. TEST the system
Measure the resistance between transfer case C350-14, for normal operation.
circuit CCF08 (GY/OG), harness side and ground; and
between the transfer case C350-15, circuit CCF07

X29 CHECK FOR CORRECT TCCM OPERATION
Yes
damaged pins
pushed-out pins. No
2952
CORRECT
Connect all TCCM connectors and make sure they are The system is operating correctly at
seated correctly. this time. Concern may have been
Is the concern still present? connector. ADDRESS the root cause
of the connector concern. TEST the
X30 SHIFT THE TRANSFER CASE TO 4H MANUALLY
Yes
Remove the transfer case shift motor from the transfer GO to X31 .
case.
Using a suitable wrench, rotate the shift cam to the 4H No
position. REPAIR the transfer case. REFER to
Rotate the rear driveshaft and watch the front driveshaft. Section 308-07B .
Does the transfer case shift to 4H and the front
driveshaft rotates?
X31 CHECK THE TORQUE REQUIRED TO SHIFT THE
TRANSFER CASE
Yes
Rotate the shift cam by hand through 4L, 4H and 2H GO to X32 .
positions.
Measure the torque required to perform the shift. No
Is the torque required to shift 45 Nm (33 lb-ft) or less? REPAIR the transfer case. REFER to
Section 308-07B .
X32 SHIFT THE TRANSFER CASE TO 2H MANUALLY
Yes
Rotate the shift cam to the 2H position. GO to X33 .
Rotate the rear driveshaft and watch the front driveshaft.
Does the transfer case shift to 2H and the front No
driveshaft does not rotate? REPAIR the transfer case. REFER to
Section 308-07B .
X33 SHIFT THE TRANSFER CASE TO 4L MANUALLY
Yes
Rotate the shift cam by hand to the 4L position. INSTALL a new transfer case shift
Rotate the rear driveshaft and watch the front driveshaft. motor. REFER to Transfer Case
Does the transfer case shift to 4L and the front Shift Motor in this section. CLEAR
driveshaft rotates? the DTCs. TEST the system for
normal operation.
No
REPAIR the transfer case. REFER to
Section 308-07B .
2953
CORRECT
2954
CORRECT

Manual
4X4 Control Module

1 06010 Glove compartment assembly
2 W705314 Screws
3 7E453 4X4 control module
4 - Connector (part of 12A581)
1. Lower the glove compartment assembly to gain access.
2. Remove the two 4X4 control module screws.
4. Remove the 4X4 control module.
4X4 Control Module 2955

4X4 Control Module 2956


Manual
Integrated Wheel End (IWE)

1 1131 Dust cap
2 N802827-S Axle nut
3 W520215-S Upper ball joint nut
4 3C247 Integrated Wheel End (IWE)
5 - Vacuum vent and supply tube
6 W710279-S IWE bolts (3 required)
7 W520215-S Tie-rod nut
Removal
100-02 .
2. Remove the front wheel and tire. For additional information, refer to Section 204-04 .
3. Remove the dust cap.
4. Remove and discard the axle nut.
5. Disconnect the vacuum tubes from the Integrated Wheel End (IWE).
6. Remove the 3 IWE -to-wheel knuckle retaining bolts.
7. Remove the tie-rod nut and separate the tie rod from the wheel knuckle.
Discard the tie-rod nut.
ol>
9. Remove the front brake flexible hose bracket bolt and position the brake hose aside.
10. Remove the upper ball joint nut and separate the upper ball joint from the wheel knuckle.
Integrated Wheel End (IWE) 2957

Discard the upper ball joint nut.

11. NOTE: Allow the wheel knuckle to swing outward while keeping the halfshaft pushed
inward.
Once clearance is available, remove the halfshaft outboard end from the wheel knuckle hub
bearing.
12. Remove the IWE from the halfshaft outboard end.
Installation
1. Compress the IWE and install a vacuum cap on the vacuum port.
2. NOTICE: Do not dislodge the Integrated Wheel End (IWE) seal spring when installing
the IWE on halfshaft outboard end or component damage may occur.
Install the IWE onto the halfshaft outboard end.

3. NOTE: Allow the wheel knuckle to swing outward while keeping the halfshaft pushed
inward.
Once clearance is available, install the halfshaft outboard end into the wheel knuckle hub
bearing.
4. Connect the upper ball joint and install a new nut.
5. Connect the tie rod and install a new nut.
6. Position the front brake flexible hose bracket and install the bolt.
7. Position the wheel speed sensor harness bracket and install the bolt.
8. Install the 3 IWE -to-wheel knuckle retaining bolts.
9. Remove the IWE vacuum cap and connect the vacuum tubes.
axle nut or component damage may occur.
Install the new axle nut.

11. Install the dust cap.
12. Install the front wheel and tire. For additional information, refer to Section 204-04 .



Manual
Transfer Case Shift Motor
Material
Item Specification
Ultra Silicone Sealant -
TA-29

1 - Coil wire (part of 7G361)
2 7G360 Transfer case shift motor
3 N800670-S Transfer case shift motor bolt (3 required)
4 15525 Connector
5 - Connector inner retainer (part of 15525)
6 - Transfer case shift motor nut (part of 7G360) (2
required)
7 7A443 Transfer case shift motor bolt
Removal
100-02 .
2. Disconnect the harness connector.
3. Remove the coil wire pin from the electrical connector.

1. Remove the inner retainer from the wire connector.
2. Press the release tab and remove the coil wire pin.
Transfer Case Shift Motor 2960

4. Remove the transfer case shift motor bracket bolt and the 3 mounting bolts, then remove the transfer
case shift motor.
Installation
1. Apply a small bead of silicone sealant to the transfer case shift motor mating surface.
NOTICE: New shift motor bracket nuts are loose and are tightened last. Failure to follow the steps in
the correct order may result in damage to the component.
2. Install the transfer case shift motor and the 3 bolts.

3. Install the transfer case shift motor bracket bolt.

4. Secure the transfer case shift motor bracket nuts.

5. NOTE: After the wire is inserted into the connector, gently pull the wire back to verify the pin is
locked inside the connector.
Insert the coil wire pin in the electrical connector and install the inner connector retainer.

SECTION 308-07B: Transfer Case 2011 Expedition, Navigator Workshop Manual

Material

Motorcraft Transfer ESP-M2C166-H 1.3-1.5L (2.7-3.1
Case Fluid pt)
XL-2
Thread Sealant with PTFE WSK-M2G350-A2 -
TA-24
Ultra Silicone Sealant - -
TA-29

Coil nut 10 - 89
Connector bracket bolts 10 - 89
Crossmember bolt 90 66 -
Drain plug 15 - 133
Evaporative Emission (EVAP) canister bolt 15 - 133
Fill plug 15 - 133
LH exhaust heat shield bolt 15 - 133
RH exhaust heat shield bolt 15 - 133
Shift motor bracket "top" align="center">10 - 89
Skid plate-to-crossmember bolt 24 18 -
Skid plate-to-frame bolt 24 18 -
Transfer case bolt a - - -
Transfer case shift motor bolt 10 - 89
Transfer case shift motor bracket bolt 10 - 89
Transfer case-to-transmission bolt a - - -
Transmission mount bolt 90 66 -
Transmission mount nut 103 76 -



Transfer Case
Two-Speed Torque-On-Demand
The 2-speed torque-on-demand transfer case consists of the following components:

IWE s
Transfer case shift motor
The Borg-Warner 2-speed torque-on-demand transfer case is a 2-piece magnesium design. The transfer case
transfers engine power from the transmission to the front and rear axles. Under normal driving conditions, the
unit is in 2 wheel drive high (2H), but when desired, the operator may shift into 4 wheel drive high (4H) or 4
wheel drive low (4L). When shifting into or out of LOW range, the TCCM requires that the vehicle speed is
less than 5 km/h (3 mph) and the transmission is in NEUTRAL. The transfer case is equipped with an internal
electromagnetic clutch and is shifted electronically. This clutch is used to synchronize the front driveline. The
unit is lubricated by a positive displacement fluid pump that channels fluid flow through holes in the rear
output shaft.
One-Speed Torque-On-Demand
The 1-speed torque-on-demand transfer case consists of the following components:

IWE s
The Borg-Warner 1-speed torque-on-demand transfer case is a 2-piece magnesium design. The transfer case
transfers engine power from the transmission to the front and rear axles. Under normal driving conditions, the
unit is in All-Wheel Drive (AWD), but when desired, the operator may shift into 4 wheel drive high (4H). The
operator can switch between 2-Wheel Drive (2WD), AWD and Four-Wheel Drive (4WD) HIGH mode at any
speed. The transfer case is equipped with an internal electromagnetic clutch and is shifted electronically. In
AWD , the 4X4 control module varies the torque split between front and rear drivelines by controlling the
transfer case clutch. Under most conditions, the 4X4 control module activates the transfer case clutch at a
minimum duty cycle (percentage of time the clutch is turned on) which allows for a slight speed difference
between the front and rear drivelines which normally occurs when negotiating a corner on dry pavement.
When the rear wheels are overpowered, the 4X4 control module detects this slip condition and the duty cycle
to the transfer case clutch is increased until the speed difference between front and rear drivelines is reduced.
In this manner, the 4X4 control module can redirect engine torque to the front wheels when the rear wheels
lose traction, yet still allow operation in the AWD mode on dry pavement. The unit is lubricated by a positive
displacement fluid pump that channels fluid flow through holes in the rear output shaft.
IWE
The IWE system consists of the following components:
Transfer Case 2964

Vacuum reservoir
IWE solenoid
IWE s (spring-loaded vacuum hubs)
Vacuum hoses
Check valve
The IWE system uses vacuum hubs that engage or disengage the front wheel hubs from the front halfshafts.
The IWE solenoid receives engine vacuum from the vacuum reservoir.
When the 4 wheel drive system is in 2H mode, the TCCM supplies a ground path to the IWE solenoid to
apply vacuum to the IWE (disengaging the front hubs from the front halfshafts). In 4WD mode, the TCCM
does not supply the ground path to the IWE solenoid, vacuum is not applied to the IWE and an internal spring
keeps the front hubs engaged to the front halfshafts.
Transfer Case 2965


Transfer Case
Refer to Section 308-07A .
Transfer Case 2966


Transfer Case Draining and Filling
Special Tool(s)
Oil Suction Gun

303-D104 (D94T-9000-A)
Material
Item Specification
Motorcraft Transfer Case Fluid ESP-M2C166-H
XL-12
Thread Sealant with PTFE WSK-M2G350-A2
TA-24

1 7A110 Drain plug
2 7A110 Fill plug
100-02 .
2. NOTE: Position a drain pan under the transfer case.
Remove the drain plug and drain the fluid.
3. Clen the drain plug and the drain plug area. Apply thread sealant to the drain plug threads and install
the drain plug.
4. NOTE: Prior to removal, clean the area around the fill plug.
Remove the fill plug.
5. NOTICE: Incorrect fluid fill will result in transfer case failure.
Using the Oil Suction Gun, fill the transfer case to specification with the recommended fluid.
Transfer Case Draining and Filling 2967

Transfer case capacity is 1.3-1.5L (2.7-3.1 pt).

The fluid must be just below the fill plug hole. Fill the case until the fluid is up to the fill plug
threads.
6. Apply thread sealant to the fill plug threads, then install the fill plug.
Transfer Case Draining and Filling 2968


Transfer Case Rear Output Shaft Seal
Special Tool(s)
Installer, Input Shaft Oil Seal

308-249 (T96T-7127-A)

1 4602 Driveshaft
2 7B215 Rear output shaft seal
3 7A195 Transfer case
Removal
100-02 .
3. Using a suitable seal puller, remove the rear output shaft seal.
Installation
1. Using the Input Shaft Oil Seal Installer, install the rear output shaft seal.
Transfer Case Rear Output Shaft Seal 2969

2. Install the rear driveshaft. For additional information, refer to Section 205-01 .
Transfer Case Rear Output Shaft Seal 2970


Transfer Case - Expedition
Special Tool(s)
Handle

307-003 (T57L-500-B)
Installer, Front Axle Oil Seal

205-350 (T95T-3010-A)
Installer, Input Shaft Bearing

308-085 (T83T-7025-C)

308-186 (T90T-7127-B)

308-249 (T96T-7127-A)
Installer, Mainshaft Bearing

308-060 (T77J-7025-K)
Installer, Output Shaft Front Bearing

308-410

303-367 (T90P-6510-AH)

308-047 (T77F-1102-A)
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
XL-12
TA-29
Transfer Case - Expedition 2971

2-Speed Transfer Case - Rear Half

1 7917 Snap ring
2 7N063 Spacer
3 7D221 Caged thrust bearing
4 7G362 Hub and coil housing
5 7A534 Ball (3 required)
6 7R428 Cam
7 7D126 Wave spring
8 7917 Snap ring
9 7C108 Clutch assembly
10 7177 Drive sprocket
12 7C341 Thrust washer (2 required)
13 7A149 Oil pump assembly
14 7H298 Hose clamp
15 4090 Oil pump pickup hose
16 7A098 Oil pickup and filter
17 7G361 Transfer case field coil
18 7025 Rear output shaft support bearing
2-Speed Transfer Case - Rear Half 2972

19 7025 Front output shaft rear bearing

20 7005 Case
21 - Output shaft bushing (part of 7005)
22 7A443 Transfer case bolts (20 required)
23 7A010 Fill plug
24 7045 Coil nut (3 required)
25 N800670-S Shift motor bolt (3 required)
26 7A443C Shift motor bracket bolt
27 7G360 Transfer case shift motor
28 7H298 Inner connector retainer
29 7B215 Shift motor seal
30 7B368 Washer (3 required)
31 7H150 Armature
2-Speed Transfer Case - Front Half

31 7A153 Ring gear
32 7064 Snap ring
33 7A398 Front planet carrier
34 7D221 Front planet needle bearing
35 7D164 Reduction hub
2-Speed Transfer Case - Front Half 2973

36 7061 Output shaft

37 7C430 Shift fork pad (2 required)
38 7389 Shift fork
39 7240 Shift fork shaft
40 7F063 Shift cam assembly
41 7A029 Drive chain
42 7177 Driven sprocket
43 7917 Snap ring
44 7025 Front output shaft support bearing
45 7E290 Magnet
46 7005 Case
47 7B362 Dowel
48 7025 Front input shaft support bearing
49 7B215 Front output shaft oil seal
50 7061 Front output shaft
51 7034 Vent tube
52 7B215 Front input shaft seal
Disassembly
1. NOTICE: Use a suitable cleaning solvent to clean the transfer case. Seal all openings before
cleaning the transfer case exterior. This will prevent entry of dirt and water, which may cause
damage to internal components.
Clean the transfer case exterior with solvent and dry with compressed air.
2. Using the Transmission Holding Fixture, secure the transfer case to a work bench. Rotate the transfer
case so that the output shaft is pointing upward.
3. Drain the fluid from the transfer case, if not done previously.
4. Using a suitable seal puller, remove and discard the rear output shaft seal.

5. Remove the coil wire pin from the electrical connector.

Remove the wire connector inner retainer.
Press the release tab and remove the coil wire pin (tan wire).
6. Loosen the 2 transfer case shift motor bracket nuts and remove the bracket bolt.
7. Remove the 3 transfer case shift motor bolts and transfer case shift motor.
8. Remove the 3 coil nuts and washers.
9. NOTE: It is normal to find metal shavings after removing the self-tapping transfer case bolts.
Remove the 20 transfer case cover bolts.
10. Using the pry bosses, separate the transfer case halves.
11. Using the Bearing Cup Remover and the Slide Hammer, remove the rear output shaft support bearing.

Inspect the bearing for wear or damage. Install a new bearing as necessary.
12. Using the Bearing Cup Remover and the Slide Hammer, remove the front output shaft rear bearing.

Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
14. Remove the caged thrust bearing assembly.

15. Remove the cam/coil housing.
16. Remove the steel balls and the cam.
17. Remove the wave spring.
18. Remove and discard the snap ring.

19. NOTICE: When removing the clutch pack assembly, do not separate the clutch pack assembly.
Keep tension on the clutch pack during removal. Set the clutch pack assembly on the bench in
the same position as located in the transfer case. The thrust washer in the lower clutch pack
uses tabs to hold it in place. If the thrust washer is not in place, a transfer case clearance
problem will occur.
NOTICE: If the clutch pack is disassembled, a new clutch pack must be installed and the
armature transferred. Failure to install a new clutch pack can result in component failure.
Remove the clutch pack assembly with the armature.
20. Remove the drive chain and the sprockets as an assembly.

Inspect the drive chain for wear or damage. Inspect the sprockets for broken or cracked teeth.
Install new components as necessary.
21. Remove the thrust bearing assembly.

1. Remove the thrust washer.
The upper thrust washer may be attached to the sprocket.
Inspect the washers and bearing for wear or damage. Install new components as necessary.
22. Remove and clean the oil pan magnet.

23. Remove the output shaft sprocket.
24. Remove the oil pump assembly.
25. Remove the output shaft.
26. Remove the reduction shift fork, the reduction hub and the shift cam as an assembly.
Separate and inspect the reduction hub and the reduction shift fork for wear or damage. Do
not disassemble the shift cam assembly.

27. Remove the shift fork shaft.
28. Remove the front planet.

Using a drift and a hammer, remove the front planet needle bearing, if necessary.
29. Remove the ring gear.

2. Remove the ring gear.
30. NOTE: Do not let the front output shaft fall when removing the snap ring.
Remove the snap ring and the front output shaft.
31. NOTICE: Carefully remove the seal, do not damage the seal bore.

Remove and discard the front output shaft oil seal.
Remove and discard the front input shaft seal.
33. Using a suitable driver, remove the front planet support bearing.
34. Using a suitable driver, remove the front output shaft support bearing.
35. Using a suitable tool, remove and discard the shift shaft seal.
Assembly
1. Lubricate all internal components with the recommended transfer case lubricant during reassembly.

2. Clean the mating surfaces of the cases.
3. Using a suitable press and the Output Shaft Front Bearing Installer with the Handle, install the front
planet support bearing.
4. Using a suitable press and the Front Axle Oil Seal Installer with the Handle, install the front output
shaft support bearing.
5. Using the Input Shaft Oil Seal Installer, install a new front output shaft seal.
6. Using the Valve Stem Oil Seal Installer, install a new shift shaft seal.
7. Install the case to the Transmission Holding Fixture. Secure the case and the Transmission Holding
Fixture to the work bench.
8. Using Input Shaft Oil Seal Installer, install a new front input shaft seal.

9. Install the ring gear.

1. Position the ring gear in the case.
10. Install the front output shaft and the snap ring.
11. NOTICE: If removed, using a suitable press and the Input Shaft Bearing Installer, install the
needle bearing into the front planet. Be careful not to damage the bearing cage.
Install the front planet.
12. Install the shift fork shaft.
13. Assemble the reduction hub and the reduction shift fork. Install the reduction shift fork, the reduction
hub and the shift cam as an assembly.

14. Install the output shaft.
15. NOTE: Make sure the oil pump finger is in the slot in the case.
Install the oil pump assembly.
16. Install the oil pan magnet into the slot in the case.
17. Install the 3-piece thrust bearing assembly.

1. Install the thrust washer.

2. Install the thrust bearing.
3. Install the thrust washer.
18. Install the drive chain and the sprockets as an assembly.
19. NOTICE: When installing the clutch assembly, do not separate the clutch pack assembly. The
thrust washer in the lower clutch pack uses tabs to hold it in place. If the thrust washer is not in
place, a transfer case clearance problem will occur.
Install the clutch pack assembly with the armature.
20. Install a new snap ring.
21. Install the wave spring.
22. Install the cam and the steel balls.

23. Install the cam/coil housing.
24. Install the thrust bearing assembly.
26. Using a suitable press and the Mainshaft Bearing Installer, install the rear output shaft support
bearing.
27. Using a suitable press and the Mainshaft Bearing Installer, install the front output shaft rear bearing.
28. NOTICE: Applying too much silicone sealant will plug the fluid filter and cause transfer case
failure.
Apply a bead of silicone sealant to the transfer case mating surface, then position the 2 transfer case
halves together. Tighten the 20 transfer case bolts evenly in a star pattern.
Position the coil studs through the case holes, making sure the shift cam shaft is aligned with
its case bore and the lockup shift fork spring is in position.

29. Install the 3 coil washers and nuts.

31. Apply a small bead of silicone sealant to the transfer case shift motor mating surface.
NOTICE: When installing the shift motor, tighten the bracket nuts last. Failure to follow the steps in
the correct order may result in damage to the component.
32. Install the transfer case shift motor and the 3 bolts.
33. Install the transfer case shift motor bracket bolt.

34. Secure the transfer case shift motor bracket nuts.
36. Secure the transfer case to a suitable transmission jack and remove the transfer case from the
Transmission Holding Fixture.



Transfer Case - Navigator
Special Tool(s)
Handle

307-003 (T57L-500-B)
Installer, Front Axle Oil Seal

205-350 (T95T-3010-A)

308-186 (T90T-7127-B)

308-249 (T96T-7127-A)
Installer, Mainshaft Bearing

308-060 (T77J-7025-K)
Installer, Output Shaft Front Bearing

308-410

308-047 (T77F-1102-A)
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
XL-12
TA-29
1-Speed Transfer Case - Rear View
Transfer Case - Navigator 2988


1 7917 Snap ring
2 7N063 Spacer
4 7G362 Hub and coil housing
5 7A534 Ball (3 required)
6 7R428 Cam
7 7D126 Wave spring
8 7917 Snap ring
9 7C108 Clutch pack assembly
10 7177 Drive sprocket
12 7C341 Thrust washer (2 required)
13 7A149 Oil pump assembly
14 7H298 Hose clamp
15 4090 Oil pump pickup hose
16 7A098 Oil pickup and filter
17 7G361 Transfer case field coil
18 7025 Rear output shaft support bearing
19 7025 Front output shaft rear bearing
20 7005 Case
21 - Rear output shaft support bushing (part of 7005)
22 7A443B Transfer case bolt (20 required)
1-Speed Transfer Case - Rear View 2989

23 7A010 Fill plug

24 7045 Coil nut (3 required)
25 7A443A Connector bracket bolt (2 required)
26 7K740 Connector bracket
27 14A464 Connector
28 7B368 Washer
29 7H150 Armature
1-Speed Transfer Case - Front View

29 7061 Output shaft
30 7017 Output shaft collar
31 7A149 Input gear
32 7A029 Drive chain
34 7917 Snap ring
35 7025 Front output shaft support bearing
36 7E290 Magnet
37 7005 Case
38 7B362 Dowels
39 7025 Front input shaft support bearing
40 7B215 Front output shaft oil seal
1-Speed Transfer Case - Front View 2990

41 7061 Front output shaft

42 7034 Vent tube
43 7B215 Input flange seal
Disassembly
1. NOTICE: Use a suitable cleaning solvent to clean the transfer case. Seal all openings before
cleaning the transfer case exterior. This will prevent entry of dirt and water, which may cause
damage to internal components.
Clean the transfer case exterior with solvent and dry with compressed air.
2. Using the Transmission Holding Fixture, secure the transfer case to a work bench. Rotate the transfer
case so that the output shaft is pointing upward.
3. Drain the fluid from the transfer case, if not done previously.
4. Using a suitable tool, remove and discard the rear output shaft seal.
5. Remove the inner connector retainer. Press the release tab and remove the coil wire pin (blue wire).
6. Remove the 2 connector bracket bolts and the connector bracket.

7. Remove the 3 coil nuts and washers.
8. NOTE: It is normal to find metal shavings after removing the self-tapping transfer case bolts.
Remove the 20 transfer case bolts.
9. Using the pry bosses, separate the transfer case halves.
10. Using the Bearing Cup Remover with the Slide Hammer, remove the rear output shaft support
bearing.
11. Using the Bearing Cup Remover with the Slide Hammer, remove the front output shaft rear bearing.


13. Remove the spacer.
14. Remove the caged thrust bearing assembly.

15. Remove the cam/coil housing.
16. Remove the 3 steel balls and the cam.

17. Remove the wave spring.
18. Remove and discard the snap ring.
19. NOTICE: When removing the clutch pack assembly, do not separate the clutch pack assembly.
Keep tension on the clutch pack during removal. Set the clutch pack assembly on the bench in
the same position as located in the transfer case. The thrust washer in the lower clutch pack
uses tabs to hold it in place. If the thrust washer is not in place, a transfer case clearance
problem will occur.
Remove the clutch pack assembly with the armature.
20. Remove the drive chain and the sprockets as an assembly.

Inspect the drive chain for wear or damage. Inspect the sprockets for broken or cracked teeth.
Install new components as necessary.

21. Remove the thrust bearing assembly.

The upper thrust washer may be attached to the sprocket.
Inspect the washers and bearing for wear or damage. Install new components as necessary.
22. Remove and clean the oil pan magnet.
23. Remove the oil pump assembly.
24. Remove the output shaft.
25. Remove the input shaft.

26. NOTE: Do not let the front output shaft fall when removing the snap ring.
Remove the snap ring and the front output shaft.
Remove and discard the front output shaft oil seal.
Remove and discard the front input shaft seal.
29. Using a suitable driver, remove the front input shaft bearing.

30. Using a suitable driver, remove the front output shaft support bearing.
Assembly
1. Lubricate all internal components with the recommended transfer case lubricant during reassembly.
2. Clean the mating surfaces of the cases.
3. Using a suitable press and the Output Shaft Front Bearing Installer with the Handle, install the front
input shaft bearing.
4. Using a suitable press and the Front Axle Oil Seal Installer with the Handle, install the front shaft
support bearing.
5. Using the Input Shaft Oil Seal Installer, install a new front output shaft seal.

6. Install the case to the Transmission Holding Fixture. Secure the case and the Transmission Holding
Fixture to the work bench.
7. Using the Input Shaft Oil Seal Installer, install a new front input shaft seal.
8. Install the front output shaft and the snap ring.
9. Install the input shaft.
10. Install the output shaft.

11. NOTE: Make sure the oil pump finger is in the slot in the case.
Install the oil pump assembly.
12. Install the oil pan magnet into the slot in the case.
13. Install the 3-piece thrust bearing assembly: the thrust washer, thrust bearing and thrust washer.
14. Install the drive chain and the sprockets as an assembly.
15. NOTICE: When installing the clutch assembly, do not separate the clutch pack assembly. The
thrust washer in the lower clutch pack uses tabs to hold it in place. If the thrust washer is not in
place, a transfer case clearance problem will occur.
Install the clutch pack assembly with the armature. Make sure to align the clutch pack with the
sprocket.
16. Install a new snap ring.
17. Install the wave spring.

18. Install the cam and the steel balls.
19. Install the cam/coil housing.
20. Install the caged thrust bearing assembly.
21. Install the spacer.

23. Using a suitable press and the Mainshaft Bearing Installer, install the rear output shaft support
bearing.
24. Using a suitable press and the Mainshaft Bearing Installer, install the front output shaft rear bearing.
25. NOTICE: Applying too much silicone sealant will plug the fluid filter and cause transfer case
failure.
Apply a bead of silicone sealant to the transfer case mating surface. Position the 2 transfer case halves
together, aligning the coil studs through the case holes. Tighten the 20 transfer case bolts evenly in a
star pattern.
26. Install the 3 coil washers and nuts.


29. Install the connector bracket and the 2 connector bracket bolts.
30. Secure the transfer case to a suitable transmission jack and remove the transfer case from the
Transmission Holding Fixture.


Transfer Case

1 4A376 Front driveshaft
2 4602 Rear driveshaft
3 7E063 Skid plate
4 W503932-S Skid plate-to-crossmember bolts (2 required)
5 W503932-S Skid plate-to-frame bolts (4 required)
6 N621945-S Transmission mount nut (2 required)
7 7640124 Crossmember
8 W700140-S Transmission mount bolt (4 required)
9 6068 Transmission mount
10 - Heat shield bolt (2 required)
11 7D494 Vent hose
12 14489 Shift motor electrical connector
13 W637077-S Crossmember bolts (4 required)
14 7A443 Transfer case-to-transmission bolts (9 required)
100-02 .
2. Remove the 2 skid plate-to-crossmember bolts and the 4 skid plate-to-frame bolts and remove the skid
plate.
3. Position a hoist jack on the transmission pan rail.
Transfer Case 3003

4. Drain the fluid if the transfer case is to be disassembled.

Install the drain plug when finished draining.
7. Disconnect the shift motor electrical connector and detach the harness connector from the transfer
case.
8. Disconnect the vent hose.
9. Remove the RH exhaust heat shield.
10. Remove the LH exhaust heat shield bolt and the Evaporative Emission (EVAP) canister bolt.
11. Remove the 4 crossmember bolts and nuts.
Transfer Case 3004

12. Remove the 2 transmission mount nuts and the crossmember.
13. Remove the 4 transmission mount bolts.
14. Using a suitable transmission jack, position it to the transfer case. Secure the transfer case to the jack
with a safety strap.
15. Remove and discard the 9 transfer case-to-transmission bolts.
16. NOTE: Using soapy water in a spray bottle, lubricate the transmission mount rubbers on the exhaust.
Separate the transfer case from the transmission and move the transfer case rearward 25.4 mm (1 in).
Remove the transmission mount, then move the transfer case rearward off the output shaft and lower
it from the vehicle.
17. Remove the transfer case-to-transmission gasket and clean the mating surfaces.
Transfer Case 3005

Transfer Case 3006


Transfer Case

1 4A376 Front driveshaft
2 4602 Rear driveshaft
3 7E063 Skid plate
4 W503932-S Skid plate-to-crossmember bolts (2 required)
5 W503932-S Skid plate-to-frame bolts (4 required)
6 N621945-S Transmission mount nut (2 required)
7 7640124 Crossmember
8 W700140-S Transmission mount bolt (4 required)
9 6068 Transmission mount
10 - Heat shield bolt (2 required)
11 7D494 Vent hose
12 14489 Shift motor electrical connector
13 W637077-S Crossmember bolts (4 required)
14 7A443 Transfer case-to-transmission bolts (9 required)
1. NOTE: For models with aluminum bolts, a transmission-to-transfer case gasket is not needed. Do not
install gasket.
NOTE: Using soapy water in a spray bottle, lubricate the transmission mount rubbers.
Position the transfer case to the transmission and onto the output shaft. With the transfer case 25.4
mm (1 in) from the transmission, install the transmission mount, then seat the transfer case to the
Transfer Case 3007

transmission.
2. NOTE: Do not reuse the old transfer case-to-transmission bolts.
Install the 9 new transfer case-to-transmission bolts.
Tighten the bolts evenly in a star pattern to 17 Nm (150 lb-in).
3. Install the 4 transmission mount bolts.

4. Install the crossmember and the 2 transmission mount nuts. Do not tighten at this time.
5. Install the 4 crossmember bolts and nuts, then tighten the crossmember and transmission mount nuts.
1. Install the crossmember bolts.
2. Remove the transmission jack from under the transmission pan rail.
3. Install the crossmember nuts and tighten to 90 Nm (66 lb-ft).
4. Tighten the transmission mount nuts to 103 Nm (76 lb-ft).
6. Install the LH exhaust heat shield bolt and the Evaporative Emission (EVAP) canister bolt.
Transfer Case 3008

7. Install the RH exhaust heat shield.

8. Connect the vent hose.
9. Connect the shift motor electrical connector and attach the harness connector to the transfer case.
10. NOTE: Align the index marks made during removal.
Install the rear driveshaft. For additional information, refer to Section 205-01 .
11. NOTE: Align the index marks made during removal.
Install the front driveshaft. For additional information, refer to Section 205-01 .
12. Fill the transfer case. For additional information, refer to Transfer Case Draining and Filling in the
General Procedures portion of this section.
13. Install the skid plate and the 2 skid plate-to-crossmember bolts and the 4 skid plate-to-frame bolts.
Transfer Case 3009

Transfer Case 3010

SECTION 309-00: Exhaust System 2011 Expedition, Navigator Workshop Manual


Exhaust and transmission mounting bracket cap bolt 35 26 -
Exhaust and transmission mounting bracket-to-transmission bolts 90 66 -
Exhaust dual Y-pipe catalytic converter-to-exhaust manifold nuts a - - -
Isolator and bracket assembly-to-frame bolts 25 18 -
RH catalytic converter-to-LH catalytic converter Torca clamp nut 55 41 -
RH catalytic converter-to-muffler assembly bolts a - - -
Tail pipe-to-muffler assembly Torca clamp nut 48 35 -
Worm gear clamp 7 - 62
Transfer Case 3011


Exhaust System
The exhaust system consists of the following:
Exhaust Y-pipe dual catalytic converter

Muffler assembly
Tail pipe (Expedition models, mounted to the end of the exhaust system)
Resonator (Navigator models, mounted to the end of the exhaust system)
Exhaust System
The exhaust system provides an exit for exhaust gases and reduces engine noise by passing exhaust gases
through the catalytic converter and a muffler assembly. Rubber exhaust hanger insulators attach the exhaust
system to the mounting hooks.
Catalytic Converter
The catalytic converter plays a major role in the emission control system. The catalytic converter operates as a
gas reactor. Its catalytic function is to speed the heat-producing chemical reaction of components in the
exhaust gases in order to reduce air pollutants. The catalyst material inside the catalytic converter consists of a
ceramic substrate.
The catalytic converter is designed to provide a long life. No maintenance is necessary for the catalytic
converter.
Sound Insulators and Shields
Sound insulators and shields attached to the underbody protect the vehicle from exhaust system heat and
should be inspected at regular intervals to make sure they are not dented or out of position. If a sound
insulator or shield is damaged or shows evidence of deterioration, a new sound insulator or shield should be
installed. The sound insulators and shields for the muffler assembly and exhaust Y-pipe dual catalytic
converter are installed separately.
Precautions
NOTICE: Do not use leaded fuel in a vehicle equipped with a catalytic converter. In a vehicle that is
continually misfueled, the lead in the fuel will be deposited in the catalytic converter and completely
blanket the catalyst. Lead reacts with platinum to "poison" the catalyst. Continuous use of leaded fuel
can destroy the catalyst and render the catalytic converter useless.
NOTICE: The addition of lead to the catalytic converter can also solidify the catalyst, causing excessive
back pressure in the exhaust system and possibly causing engine damage.
NOTICE: Extremely high temperatures (1,100C [2,012F] or above) due to misfiring or over-rich
fuel/air mixture will cause the ceramic substrate to sinter or burn, destroying the catalytic converter.
Do not continue to operate the vehicle if the engine is misfiring, there is a power loss or other unusual
operating conditions, such as engine overheating and backfiring.
Exhaust System 3012

NOTICE: Do not use oil or grease-based lubricants on the isolators. These lubricants may cause
deterioration of the rubber. This can lead to separation of the isolator from the exhaust hanger bracket
during vehicle operation.
NOTE: Exhaust fasteners are of a prevailing torque design. Use only new fasteners with the same part
number as the original. Torque values must be used as specified during reassembly to make sure of correct
retention of exhaust components.
Make sure to follow these precautions when carrying out the procedures in this section.
Exhaust System 3013


Exhaust System
The exhaust system provides an exit for exhaust gases and reduces engine noise by passing exhaust gases
through the catalytic converters and a muffler assembly. The catalytic converters also play a major role in
reducing air pollutants.
1. Verify the concern by running the engine (with the vehicle on the ground) or road testing the vehicle
to duplicate the condition.
2. Visually inspect the components of the exhaust system and related controls that may affect exhaust
gas quality or loss of power.
Mechanical
Exhaust pipe pinched or crushed

Damaged muffler
Broken or damaged exhaust hanger
brackets
Damaged catalytic converter
Cracked exhaust manifold
Dirty engine Air Cleaner (ACL)
Loose or damaged heat shields
4. Verify that the exhaust system is installed correctly, with clamps correctly located and tightened to
specification.
5. If the fault is not visually evident, determine the symptom. GO to Symptom Chart - Exhaust System
Symptom Chart - Exhaust System
Symptom Chart - Exhaust System
Symptom Chart - NVH
Exhaust System 3014

Symptom Chart - NVH

Rattle, squeaks or buzz type noise - from the bottom of vehicle
Loose or damaged heat shield
INSPECT the exhaust system for loose or missing heat shields or foreign material trapped between
the heat shields and the exhaust system components. If any heat shields are loose, INSTALL worm
gear clamp 7L5Z-5A231-AA and tighten to 7 Nm (62 lb-in). If the heat shields are missing,
INSTALL new heat shields or exhaust system components as necessary. If a rattle, noise or buzz
condition persists, INSTALL a new heat shield or component as necessary. TEST the system for
normal operation after the repair.
Loose or damaged exhaust isolators
CHECK that the exhaust isolators are correctly installed. INSPECT the exhaust isolators for wear or
damage. INSTALL new isolators as necessary. TEST the system for normal operation after the repair.
Damaged exhaust isolator hanger bracket
INSPECT the exhaust system components for damage or broken hangers. INSTALL new components
as necessary. CHECK for loose or damaged exhaust hanger brackets or fasteners. TIGHTEN bolts to
specification or INSTALL new components as necessary. TEST the system for normal operation after
the repair.
Catatic converter
Muffler
MOVE the exhaust system to simulate the bouncing action of the vehicle, checking for
exhaust-to-body contact while moving the exhaust system. Using a rubber mallet, lightly TAP on the
exhaust components one at a time to duplicate the noise concern. DETERMINE if there are any loose
or broken baffles or elements. REPAIR or INSTALL new components as necessary. TEST the system
for normal operation after the repair.
Exhaust grounded to chassis
INSPECT for signs of exhaust components-to-body contact. If necessary, CARRY OUT the Exhaust
System Alignment in this section.
Drone or clunk type noise - from bottom of vehicle
INSPECT exhaust isolators for wear or damage. INSTALL new isolators as necessary. TEST the
system for normal operation after the repair.
Exhaust System 3015

Exhaust grounded to chassis
INSPECT for signs of exhaust components-to-body contact. If necessary, CARRY OUT the Exhaust
System Alignment in th section.
Whistles, boom, hum or ticking type noise - noise tends to change as engine warms. Noises are often
accompanied by exhaust fumes
Exhaust system leak
INSPECT the entire exhaust system for leaks. CHECK for punctures, loose or damaged
clamps/fasteners, gaskets, sensors or broken welds. EXAMINE the chassis for grayish-white or black
exhaust soot, which would indicate exhaust leakage at that point. To magnify a small leak, have an
assistant hold a rag over the tail pipe outlet, while listening for a leak. REPAIR or INSTALL new
components as necessary. TEST the system for normal operation after the repair.
Catalytic converter
Muffler
or broken baffles or element. REPAIR or INSTALL new components as necessary. TEST the system
Exhaust muffler/resonator drain hole enlarged due to corrosion
NOTE: Check with vehicle on the ground, not on a hoist.
CONFIRM drain holes are noise source. INSTALL new components as necessary. TEST the system
Thermal expansion of exhaust versus heat shields
This is a normal condition.
Hissing or rushing noise - high frequency sound. Vehicle performance is unaffected
Exhaust system. Exhaust flow through pipes
or broken baffles or element. CHECK for missing or leaking Torca clamps. REPAIR or INSTALL
new components as necessary. TEST the system for normal operation after the repair.
Pinging noise - occurs when exhaust system is hot, engine turned off
Catalytic converter/exhaust system

Thermal expansion of exhaust system
Cool down pinging is the exhaust system expanding and contracting during heating and cooling. This
is a normal condition.
Exhaust System 3016

Vibration - occurs at idle and at low speeds. Also accompanied by clunk or buzz type noise
INSPECT the exhaust isolators for wear or damage. INSTALL new isolators as necessary. TEST the
system for normal operation after the repair.
Loose or damaged exhaust isolator hanger brackets
INSPECT the exhaust isolator hanger brackets for wear or damage. INSTALL or REPAIR as
necessary. TEST the system for normal operation after the repair.
Damper broken or out of position if equipped
Exhaust system grounded to chassis
CARRY OUT the Exhaust System Alignment in this section.
Engine drumming noise - normally accompanied by vibration
Damaged or misaligned exhaust system
INSPECT the exhaust system for loose or damaged fasteners, Torca clamps or isolators. CARRY
OUT the Exhaust System Alignment in this section. TEST the system for normal operation after the
repair.
Sputter type noise - noise worse when cold, lessens or disappears when the vehicle is at operating
temperature
Damaged or worn exhaust system
INSPECT the exhaust system for leaks or damage. REPAIR as necessary. TEST the system for
normal operation after the repair.
Thumping noise - from the bottom of the vehicle, worse at acceleration
Misaglined exhaust system
CHECK the exhaust system-to-chassis clearance. CHECK the exhaust system isolators for damage.
REPAIR as necessary. TEST the system for normal operation after the repair.
Engine vibration - is felt with increases and decreases in engine rpm
Strain on exhaust system isolators
CARRY OUT the Exhaust System Alignment in this section. REPAIR as necessary. TEST the system
Drumming noise - occurs inside the vehicle during idle or high idle, hot or cold. Very low-frequency
drumming is very rpm dependent
Exhaust system vibration excites the body resonances inducing interior noise
Exhaust System 3017

Pinpoint Test
Pinpoint Test A: Drumming Noise
This pinpoint test is intended to diagnose the fog:

Exhaust system
PINPOINT TEST A: DRUMMING NOISE

A1 CHECK THE EXHAUST SYSTEM
Yes
Start the engine. REFER to Exhaust System
Increase the engine rpm until the noise is the loudest. Note Alignment in this section. TEST the
the engine rpm. system for normal operation.
Ignition OFF.
Add approximately 9 kg (20 lb) of weight to the exhaust No
system. First place the weight at the tail pipe and test, then CONDUCT a diagnosis on other
at the front pipe. suspect systems. REFER to Section
Start the engine. 100-04 .
Increase the engine rpm and listen for the drumming noise.
Note the engine rpm if the noise occurs.
Ignition OFF.
Determine the amount of vibration that occurs with the
drumming noise.
Is the noise/vibration reduced or eliminated, or does
the noise/vibration occur at a different rpm?
PINPOINT TEST A: DRUMMING NOISE 3018

PINPOINT TEST A: DRUMMING NOISE 3019


Exhaust System Alignment
100-02 .
2. NOTE: LH side shown, RH side similar.
If equipped, remove the 6 bolts and transfer case skid plate.
3. Loosen all exhaust component fasteners from the exhaust manifolds to the muffler inlet pipe except
the RH catalytic converter-to-LH catalytic converter Torca clamp.
4. Verify that the RH catalytic converter-to-LH catalytic converter and tail pipe clamps are secure and
pipes are fully inserted.
5. NOTE: Make sure the exhaust isolators are not torn, damaged or binding.
Beginning at the front of the vehicle, align the exhaust system to establish the maximum clearance to
surrounding components. Make sure that all slip fit pipes are pushed all the way into the preceding
pipe and the notches are correctly lined up with the tabs.
6. Tighten the 2 RH catalytic converter-to-exhaust manifold nuts in the following sequence:

1. Tighten the RH lower catalytic converter-to-exhaust manifold nut.
2. Tighten the RH upper catalytic converter-to-exhaust manifold nut.
7. Tighten the exhaust and transmission mounting bracket cap bolt.

Exhaust System Alignment 3020

8. If loosened, tighten the RH catalytic converter-to-LH catalytic converter Torca clamp.

9. Tighten the 2 LH catalytic converter-to-exhaust manifold nuts in the following sequence:

1. Snug the LH inner catalytic converter-to-exhaust manifold nut.
2. Tighten the LH outer catalytic converter-to-exhaust manifold nut.
3. Tighten the LH inner catalytic converter-to-exhaust manifold nut.
10. Tighten the 2 exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts in the following
sequence:
1. Snug the outer exhaust Y-pipe dual catalytic converter-to-muffler assembly bolt.
2. Tighten the inner exhaust Y-pipe dual catalytic converter-to-muffler assembly bolt.
3. Tighten the outer exhaust Y-pipe dual catalytic converter-to-muffler assembly bolt.
11. Start the engine and check the exhaust system for leaks.
If equipped, install the transfer case skid plate and 6 bolts.



Exhaust System - Exploded View
Expedition and Navigator
Part
1 6068 Exhaust and transmission mounting bracket
2 W711140 Exhaust and transmission mount bolts (3 required)
3 W520514 Exhaust Y-pipe dual catalytic converter-to-exhaust
manifold nut (4 required)
4 5E212 RH catalytic converter
5 W713248 RH catalytic converter-to-muffler assembly bolts (2
required)
6 5A231 RH catalytic converter-to-LH catalytic converter Torca
clamp
7 5E212 LH catalytic converter
8 5230 Muffler assembly
9 5A231 Muffler assembly-to-resonator Torca clamp
10 W500225 Isolator and bracket assembly bolts (2 required)
11 5202 Tail pipe
12 5A231 Muffler assembly-to-tail pipe Torca clamp
13 W500225 Isolator and bracket assembly boltsuired)
14 5201 Resonator
15 5260 Isolator and bracket assembly
Exhaust System - Exploded View 3023


(part of 9D930) (2 required)
Expedition EL and Navigator L
Part
1 6068 Exhaust and transmission mounting bracket
2 W711140 Exhaust and transmission mount bolts (3 required)
3 W520514 Exhaust Y-pipe dual catalytic converter-to-exhaust
manifold nut (4 required)
4 5E212 RH catalytic converter
5 W713248 RH catalytic converter-to-muffler assembly bolts (2
required)
6 5A231 RH catalytic converter-to-LH catalytic converter Torca
clamp
7 5E212 LH catalytic converter
9 5A231 Muffler assembly-to-resonator Torca clamp
11 5202 Tail pipe
12 5A231 Muffler assembly-to-tail pipe Torca clamp
Expedition and Navigator 3024


14 5201 Resonator
15 5260 Isolator and bracket assembly
(part of 9D930) (2 required)
Expedition EL and Navigator L 3025


Exhaust Y-Pipe - Dual Catalytic Converter
Removal
NOTICE: Do not use oil or grease-based lubricants on isolators as they deteriorate the rubber.
NOTE: The exhaust Y-pipe dual catalytic converter is a 2-piece assembly. The RH and LH converters can be
serviced separately as needed.
All vehicles
100-02 .
2. Disconnect the Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) electrical
connectors.
3. Remove the transmission support crossmember. For additional information, refer to Section 502-02 .
4. Loosen the exhaust and transmission mounting bracket cap bolt.
5. Remove the 3 bolts and then slide off the exhaust and transmission mounting bracket from the exhaust
Y-pipe dual catalytic converter.
Exhaust Y-Pipe - Dual Catalytic Converter 3026

6. NOTE: On Four-Wheel Drive (4WD) vehicles, the exhaust and transmission mounting bracket will
not slide off the exhaust Y-pipe dual catalytic converter until the exhaust Y-pipe dual catalytic
converter is removed from the vehicle.
Remove the 4 bolts from the exhaust and transmission mounting bracket.
All vehicles
7. Remove the 2 exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts.
8. NOTE: LH catalytic converter-to-exhaust manifold nuts shown, RH similar.
Remove the 4 exhaust Y-pipe dual catalytic converter-to-exhaust manifold nuts.
Discard the nuts.
9. Remove the exhaust Y-pipe dual catalytic converter from the vehicle.
4WD vehicles
10. If necessary, remove the exhaust and transmission mounting bracket from the exhaust Y-pipe dual
catalytic converter.
All vehicles
11. If necessary, loosen the RH catalytic converter-to-LH catalytic converter Torca clamp.
12. If necessary, separate the RH catalytic converter from the LH catalytic converter.
Installation
All vehicles
NOTICE: Do not tighten the fasteners until all components are assembled and aligned, making sure to
tighten all fasteners beginning at the front of the vehicle. For additional information, refer to Exhaust
System Alignment in this section.

NOTE: Clean the mating surfaces of the exhaust manifold outlet flare and the exhaust Y-pipe dual catalytic
converter inlet flares.
Also clean the mating surfaces of the exhaust Y-pipe dual catalytic converter-to-muffler assembly.
1. If separated, install RH catalytic converter to the LH catalytic converter.
4WD vehicles
2. If removed, install the exhaust and transmission mounting bracket to the exhaust Y-pipe dual catalytic
converter.
All vehicles
3. Position the exhaust Y-pipe dual catalytic converter into the vehicle.
4. Install the 2 new RH catalytic converter-to-exhaust manifold nuts and tighten in the following
sequence:
1. Tighten the RH lower catalytic converter-to-exhaust manifold nut.
2. Tighten the RH upper catalytic converter-to-exhaust manifold nut.
5. Install the 2 new LH catalytic converter-to-exhaust manifold nuts and tighten in the following
sequence:
1. Snug the LH inner catalytic converter-to-exhaust manifold nut.
2. Tighten the LH outer catalytic converter-to-exhaust manifold nut.
3. Tighten the LH inner catalytic converter-to-exhaust manifold nut.
6. If loosened, tighten the RH catalytic converter-to-LH catalytic converter Torca clamp.


7. Install the 2 exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts and tighten in the
following sequence:
4WD vehicles
8. NOTE: RH side shown, LH side similar.
Install the 4 exhaust and transmission mounting bracket-to-transmission bolts.
RWD vehicles
9. Slide on the exhaust and transmission mounting bracket to the exhaust Y-pipe dual catalytic converter
and install the 3 exhaust and transmission mounting bracket-to-transmission bolts.
All vehicles
10. Tighten the exhaust and transmission mounting bracket cap bolt.

11. Install the transmission support crossmember. For additional information, refer to Section 502-02 .
12. Connect the HO2S and CMS electrical connectors.
13. Check to see if the exhaust system isolators are at zero load. If the exhaust system isolators are not at
zero load, then carry out the exhaust system alignment procedure. For additional information, refer
the Exhaust System Alignment in this section.


Muffler and Tailpipe
Removal
deterioration of the isolator. This can lead to separation of the isolator from the exhaust hanger bracket
during vehicle operation.
100-02 .
If equipped, remove the 6 bolts and transfer case skid plate.
3. Loosen the tail pipe or resonator-to-muffler assembly Torca clamp.
4. Remove the 2 isolator and bracket assembly bolts and remove:

the tail pipe for Expedition models.
the resonator for Navigator models.
5. Using a suitable jackstand, support the muffler.
6. Remove the 2 exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts.
7. NOTICE: Make sure not to make contact with the axle boots while routing the muffler assembly
outlet over the rear axle or damage to the boots may result.
Muffler and Tailpipe 3031

Detach the isolators from the muffler assembly and remove from the vehicle.
Installation
deterioration of the isolator. This can lead to separation of the isolators from the exhaust hanger
bracket during vehicle operation.
1. NOTE: Clean the mating surfaces of the exhaust Y-pipe dual catalytic converter-to-muffler assembly.
NOTE: Check the exhaust hanger isolators for wear or damage, install new isolators, if necessary.
Install the muffler assembly into the vehicle and attach the isolators.
2. Install the 2 exhaust Y-pipe dual catalytic converter-to-muffler assembly bolts and tighten in the
following sequence:
3. Install the tail pipe for Expedition models or the resonator for Navigator models and install the
isolator and 2 bracket assembly bolts.
4. Tighten the tail pipe or resonator-to-muffler assembly Torca clamp.

5. Check to see if the exhaust system isolators are at zero load. If the exhaust system isolators are not at
zero load, then carry out the exhaust system alignment procedure. For additional information, refer
the Exhaust System Alignment in this section.


SECTION 310-00: Fuel System - General Information 2011 Expedition, Navigator Workshop Manual
Material

Capacity
or equivalent
Item Specification
Fuel tank capacity (Expedition and Navigator) 106L (28.0 gal)
Fuel tank capacity (Expedition EL and Navigator L) 127L (33.5 gal)
Fuel Pressure
Engine running 379-414 kPa (55-60 psi)
Key ON Engine OEO) 379-414 kPa (55-60 psi)


SECTION 310-00: Fuel System - General Information
Manual
Fuel System
The fuel system consists of the following:
Fuel rail
Fuel injectors
Fuel tank
Fuel Pump (FP) module (located in the fuel tank)
Fuel supply tube
Easy Fuel TM (capless) fuel tank filler pipe assembly (which cannot be modified)
Lifetime fuel filter (serviced as part of the FP module)
Supplemental refueling adapter located in the spare tire compartment
2-speed Mechanical Returnless Fuel System (MRFS)
The vehicle is equipped with a Multi-Port Fuel Injection (MFI) system.
Fuel delivery is accomplished through a MRFS .
The FP supplies the fuel injectors with pressurized fuel through the fuel rail.
The fuel injectors are sepely controlled and mounted to the intake manifold for each cylinder.
The fuel tubes route the fuel from the fuel pump to the fuel rail.
The fuel filter cleans the fuel delivered from the FP to the fuel rail.
Fuel Pump (FP) Shut-off Feature
In the event of a moderate to severe collision, the vehicle is equipped with a FP shut-off feature that is
initiated by the event notification signal.
The event notification signal is a signal provided by the Restraints Control Module (RCM) to the FP control
module. Signal communication between the RCM and the FP control module allows the PCM to initiate
secondary fuel cut off to shut off the FP .
Should the vehicle shut off after a collision due to this feature, the vehicle may be restarted by resetting the
Inertia Fuel Shutoff (IFS) switch located behind LH rear quarter trim panel access cover.
For exploded view information of the fuel system, refer to Fuel Tank and Filler Pipe - Exploded View or Fuel
Lines and Fuel Filter - Exploded View in Section 310-01 .
Fuel System 3035

Fuel System 3036


SECTION 310-00: Fuel System - General Information
Manual
Fuel System
Special Tool(s)


NOTE: The following procede diagnoses a slow-to-fill concern only. For all other concerns, refer to the
Powertrain Control/Emissions Diagnosis (PC/ED) manual.
The fuel tank filler pipe assembly is used to refuel the vehicle. The fuel tank inlet check valve prevents
spitback of fuel during and after refueling. The fuel tank stores the fuel. The fuel tank contains a Fuel Pump
(FP) module. The FP module consists of a fuel level sender and a FP . The fuel level sender sends a signal to
the fuel gauge informing the driver of how much fuel is in the fuel tank. The FP provides fuel to the fuel tubes
which supply the fuel rail.
During refueling, the fuel tank vents to the atmosphere through the vent and filler pipes, on vehicles without
On-Board Refueling Vapor Recovery (ORVR) systems. In vehicles equipped with ORVR , the fuel tank and
filler pipe are designed so that when the vehicle is being refueled, fuel vapors in the fuel tank travel to the
Evaporative Emission (EVAP) canister, which absorbs the fuel vapors and vents the pressure from the fuel
tank during refueling.
Fuel System 3037

NOTE: Do not use incandescent lights when inspecting the fuel system. Use only flourescent or LED
lighting.
1. Verify the customer concern by refueling the vehicle and observe the fuel fill rate.
2. Inspect to determine if any of the following mechanical concerns apply.
Mechanical
Bent, kinked or damaged fuel tank filler pipe

Bent, kinked or damaged fuel tank filler pipe vent tube (if equipped)
Incorrect routing of the fuel tank filler pipe
Incorrect routing of the fuel tank filler pipe vent tube (if equipped)
Incorrect position of fuel tank filler pipe clamps
Incorrect position of fuel tank filler pipe vent tube clamps (if equipped)
Fuel tank mounted vapor tubes bent or damaged
Evaporative Emission (EVAP) system tubes or hoses bent or damaged
Accident damage to the fuel tank
Accident damage to the vehicle affecting the fuel tank filler pipe-to-body
connection
Unauthorized modifications and/or alterations to the vehicle
EVAP system fresh air hose plugged (dirt, spider webbing)



418-00 .
Fuel System 3038

(CMDTCs).
8. Clear the continuous DTCs and carry out the self-test diagnostics for the EVAP system using the scan
tool.
9. If the DTCs retrieved are related to the concern, go to Evaporative Emission (EVAP) System DTC
Chart. For PCM-related DTCs, refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
For all other DTCs, refer to Section 419-10 .
DTC Chart
Evaporative Emission (EVAP) System DTC Chart

P0446 Evaporative Emission System Vent Control Circuit GO to Pinpoint Test A .
P0451 Evaporative Emission System Pressure Sensor/Switch Range/Performance GO to Pinpoint Test A .
P0452 Evaporative Emission System Pressure Sensor/Switch Low GO to Pinpoint Test A .
P0453 Evaporative Emission System Pressure Sensor/Switch High GO to Pinpoint Test A .
P0454 Evaporative Emission System Pressure Sensor/Switch Intermittent GO to Pinpoint Test A .
P1450 Unable to Bleed up Fuel Tank Vacuum GO to Pinpoint Test A .
P1451 Evaporative Emission System Vent Control Circuit GO to Pinpoint Test A .
P260F Emission System Monitoring Processor Performance GO to Pinpoint Test A .
Symptom Chart
Symptom Chart
Pinpoint Test
Pinpoint Test A: Slow to Fill
Normal Operation
Under normal operation, fuel should flow at a steady rate through the fuel tank filler pipe into the fuel tank.
As fuel enters the fuel tank, air is vented through the filler pipe or the On-Board Refueling Vapor Recovery
(ORVR) system.

Fuel tank filler pipe vent tube, if equipped
Fuel tank filler pipe
Evaporative Emission (EVAP) system
Fuel tank inlet check valve (part of the fuel tank)
Fuel level vent valve, if equipped

PINPOINT TEST A: SLOW TO FILL

A1 CARRY OUT INSPECTION AND
VERIFICATION
Yes
Carry out Inspection and Verification. REPAIR or INSTALL new components to correct
Was the cause of the concern found? the concern.
No
GO to A2 .
A2 CHECK THE SYSTEM FOR ANY EVAP
DTCs
Yes
Connect the scan tool. REFER to Powertrain Control/Emissions Diagnosis
Check the system for any of the following (PC/ED) manual to diagnosis the EVAP system.
EVAP DTCs: P0446, P0451, P0452,
P0453, P0454, P1450, P1451 and P260F. No
Are any of these DTCs present? GO to A3 .
A3 MONITOR THE FTP WHILE FILLING
THE FUEL TANK
Yes
Monitor the Fuel Tank Pressure (FTP) GO to A5 .
reference value while filling the fuel tank.
Refer to the Reference Values in the No
Powertrain Control/Emissions Diagnosis GO to A4 .
(PC/ED) manual.
Is FTP within specification?
A4 MONITOR THE FTP WHILE FILLING
THE FUEL TANK WITH THE EVAP
SYSTEM DISCONNECTED
Yes
Disconnect the fuel tank-to- EVAP canister INSPECT the EVAP system for blockage or
quick connect coupling at the EVAP restrictions. REPAIR the blockage or restriction. If
canister. the blockage or restriction cannot be repaired,
Monitor the FTP reference value while INSTALL new EVAP system components.
filling the fuel tank. Refer to Powertrain
Control/Emissions Diagnosis (PC/ED) No
manual. GO to A5 .
Is FTP within specification?
A5 CHECK THE FUEL TANK FILLER PIPE
ASSEMBLY FOR BLOCKAGE OR
RESTRICTION
Yes
Remove the fuel tank filler pipe assembly. If possible, REPAIR the blockage or restriction. If
Refer to Section 310-01 . the blockage or restriction cannot be repaired,
Inspect the fuel tank filler pipe and fuel INSTALL a new fuel tank filler pipe or fuel tank
tank filler pipe vent tube (if equipped) for a filler pipe vent tube.
blockage or restriction.
No
PINPOINT TEST A: SLOW TO FILL 3040

Is the fuel tank filler pipe or fuel tank GO to A6 .

filler pipe vent tube (if equipped)
blocked or restricted?
A6 CHECK THE FUEL TANK INLET
CHECK VALVE
Yes
Inspect the fuel tank inlet check valve for If possible, REPAIR the restrictions. If the
restriction or sticking. restriction cannot be repaired, INSTALL a new fuel
Is the fuel tank inlet check valve tank. REFER to Section 310-01 .
restricted or sticking?
No
GO to A7 .
A7 CHECK TO MAKE SURE THAT THE
FUEL LEVEL VENT VALVE IS
FUNCTIONING CORRECTLY
Yes
NOTE: The fuel level vent valve, if Fuel level vent valve is OK. RETEST the system for
equipped, is part of the FP module. normal operation.
Remove the FP module. Refer to Section
310-01 . No
Inspect the fuel level vent valve for foreign INSTALL a new FP module. REFER to Section
material at the bottom drain hole. 310-01 .
Invert the FP . Watch for a movement and a
click noise.
Was a movement/click noise witnessed?
PINPOINT TEST A: SLOW TO FILL 3041

Fuel System Pressure Release
Special Tool(s)
Fuel Pressure Test Kit

310-D009 (D95L-7211A) or equivalent
on or near any fuel-related component. Highly flammable mixtures are always pre and may be ignited.
2. Remove the cap from the fuel pressure relief valve located on the fuel rail.
3. Install the Fuel Pressure Test Kit onto the fuel pressure relief valve.
4. NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the
fuel system. Place fuel in a suitable container.
Fuel System Pressure Release 3042

Open the manual valve on the Fuel Pressure Test Kit and relieve the fuel pressure.
5. NOTE: It may take more than one key cycle to pressurize the fuel system.
Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before
starting the engine.
Fuel System Pressure Release 3043

Fuel System Pressure Test
Special Tool(s)
Fuel Pressure Test Kit

310-D009 (D95L-7211A) or equivalent
ignited. Failure to follow these instructiony result in serious personal injury.
1. Remove the cap from the fuel pressure relief valve located on the fuel rail.
2. Install the Fuel Pressure Test Kit onto the fuel pressure relief valve.
3. Test the fuel system pressure to make sure it is within the specified range. For additional information,
4. NOTE: Open the drain valve slowly to relieve the fuel system pressure. This may drain fuel from the
system. Place fuel in a suitable container.
Fuel System Pressure Test 3044

Upon completion of the fuel system pressure test, open the drain valve on the Fuel Pressure Test Kit
and relieve the fuel system pressure.
5. NOTE: It may take more than one key cycle to pressurize the fuel system.
Cycle the ignition key and wait 3 seconds to pressurize the fuel system. Check for leaks before
starting the engine.
Fuel System Pressure Test 3045

Fuel Tank Draining
Special Tool(s)
100 Gallon Gasoline Hand Pump Storage

Tanker
WARNING: Do not smoke, carry lighted tobacco or have an open flame ny type when working on
or near any fuel-related component. Highly flammable mixtures are always present and may be ignited.
1. If equipped, turn the air suspension switch OFF.
100-02 .
3. Release the fuel system pressure. For additional information, refer to Fuel System Pressure Release in
this section.
5. Disconnect the fuel tank filler pipe from the fuel tank.
6. NOTE: Do not use a hose larger than 13 mm (0.5 in) diameter.
NOTE: Follow the operating instructions of the equipment manufacturer.
Fuel Tank Draining 3046

Using the hose of the 100 Gallon Gasoline Hand Pump Storage Tanker, pump the fuel from the fuel
tank opening into the 100 Gallon Gasoline Hand Pump Storage Tanker.
Fuel Tank Draining 3047

Quick Connect Coupling
Material
Item Specification
or equivalent
Disconnect - Type I
any foreign material from the connector retaining clip area before separating from the tube or damage
to the tube or connector retaining clip can occur. Apply clean engine oil to the end of the tube before
inserting the tube into the connector.
essential that absolute cleanliness is observed when working with these components or component
damage can occur. Always install blanking plugs to any open orifices or tubes.
1. NOTICE: Do not use any tools. The use of tools may cause a deformity in the clip components
which may cause fuel leaks.
Disconnect the quick connect coupling.
Push the connector toward the tube to release pressure.

Push the release tab clockwise.
Disconnect the quick connect coupling.
Connect - Type I
Quick Connect Coupling 3048

1. Inspect and clean both quk connect coupling ends.
NOTE: Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel
tube is fully seated, pull on the tube.
NOTE: Apply clean engine oil to the end of the tube and the quick connect coupling O-ring seals.
Connect the quick connect coupling.
Disconnect - Type II
ignited.ailure to follow these instructions may result in serious personal injury.
1. If servicing a liquid fuel tube quick connect coupling, release the fuel system pressure. For additional
information, refer to Fuel System Pressure Release in this section.

NOTE: When reusing liquid or vapor tube quick connect couplings, make sure to use compressed air
to remove any foreign material from the tube. Apply clean engine oil to the end of the tube before
connecting the quick connect coupling.
Spread the legs of the retainer clip and pull it to the outward position in the quick connect coupling.
4. Depress the retainer clip and disconnect the quick connect coupling from the tube.
Connect - Type II
1. Install the quick connect coupling onto the tube until fully seated.
NOTE: Make sure the retainer clip is fully seated and locked onto the tube by pulling on the quick
connect coupling.
Press the retainer clip into the quick connect coupling body until flush and the legs are locked in
place.

Disconnect - Type III
1. If servicing a liquid fuel tube, release the fuel system pressure. For additional information, refer to
Fuel System Pressure Release in this section.
Disconnect the fuel tube quick connect coupling.
Press the fuel tube quick connect coupling button and pull the fuel tube to disconnect.

Connect - Type III
1. Inspect and clean both quick connect coupling ends.
2. <NOTE: Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel
Install the quick connect coupling onto the tube until it is fully seated.
Disconnect - Type IV

Disconnect the fuel tube quick connect coupling.
Press the 2 fuel tube quick connect coupling buttons and pull the fuel tube to disconnect.
Connect - Type IV
2. NOTE: Make sure the fuel tube clicks into place when installing the tube. To make sure that the fuel
Install the quick connect coupling onto the tube until it is fully seated.
Disconnect - Type V

Depress the legs of the retainer clip and position the clip to the outward position.
4. Disconnect the quick connect coupling from the fuel tube.
Connect - Type V

2. NOTE: Apply clean engine oil to the end of the tube and the quick connect coupling O-ring seals.
Install the quick connect coupling onto the fuel tube until fully seated.
NOTE: Make sure the retainer clip is fully seated and locked onto the fuel tube by pulling on the
quick connect coupling.
Press the retainer clip into the quick connect coupling body until flush and the legs are locked in
place.
Disconnect - Type VI

Unclip the locking tab.
4. Depress the tabs and press the clip downward.
5. Separate the quick connect coupling.
Connect - Type VI
Connect the tube into the quick connect coupling.

Push the clip up into the quick connect coupling. Pull on the tube to make sure it is seated correctly.
4. Clip the locking tab into place.
Disconnect - Type VII
WARNING: Do not carry personal electronic devices such as cell phones, pagers or audio uipment
of any type when working on or near any fuel-related component. Highly flammable mixtures are
always present and may be ignited. Failure to follow these instructions may result in serious personal
injury.

Squeeze the quick connect coupling retainer locking tabs to release the locking mechanism.
4. Push the locking mechanism outward to release the tube.
5. Remove the quick connect coupling from the tube.
Connect - Type VII
Install the quick connect coupling onto the tube.

Depress the quick connect coupling locking mechanism into the lock position.
4. Visually inspect and verify that the locking mechanism is flush with the quick connect coupling
housing anthat the locking tabs are securely fastened.
5. Pull on the quick connect coupling and the tube to make sure it is securely fastened.


Vapor Tube Fittings
Material
Item Specification
or equivalent
Disconnect
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on
or near any fuel-related component. Highly flammable mixtures are always present and may be ignited.
Disconnect the vapor tube fitting.
Push the connector toward the tube or fitting to release pressure.

Press the quick connect fitting button and pull the fuel tube to disconnect.
Vapor Tube Fittings 3061

Connect
NOTE: Apply clean engine oil to the end of the tube or fitting before connecting.
Connect the vapor tube fitting.

SECTION 310-01: Fuel Tank and Lines 2011 Expedition, Navigator Workshop Manual

Fuel Pump (FP) module cover nuts 9 - 80
Fuel tank filler pipe-to-body screws 1 - 9
Fuel tank filler pipe-to-frame bolts 15 - 133
Fuel tank filler pipe-to-fuel tank hose clamp 3 - 27
Fuel tank support strap bolts 40 30 -
Inertia Fuel Shutoff (IFS) switch bolts 2 - 18
Selector lever bracket bolts 48 35 -
Skid plate nuts 20 - 177
Sway bar bracket nuts 48 35 -

Fuel Tank and Lines
The fuel system consists of the following:
Fuel tank assembly

Easy Fuel TM (capless) fuel tank filler pipe assembly (which cannot be modified in any way)
Lifetime fuel filter, (serviced as part of the Fuel Pump (FP) module)
Fuel tube(s)
Fuel vapor tubes
Fresh air tube (located on top of the transmission)
FP module containing:
the electric FP , which provides pressurized fuel to the engine.
the fuel level sensor.
an inlet filter.
a check valve which maintains system pressure after the pump is shut off.
a pressure regulator.
The FP is controlled by the PCM. Electrical power to the pump is provided through the Inertia Fuel Shutoff
(IFS) switch.
Fuel Tank and Lines 3064

Fuel Tank and Lines
Fuel Tank and Lines 3065

Fuel Tank and Filler Pipe - Exploded View

assembly-to-Evaporative Emission (EVAP) canister
2 - Fuel tank fuel supply tube-to-front fuel supply tube
quick connect coupling (part of 9J280)
3 - FTP sensor electrical connector (part of 14405)
4 - Fuel Pump (FP) module electrical connector (part of
14405)
5 W705392 Fuel tank filler pipe-to-body screw (3 required)
6 9034 Fuel tank filler pipe
7 W704901 Fuel tank filler pipe bracket-to-frame bolts (2 required)
8 - Fuel tank filler pipe vent tube-to-fuel tank pressure
sensor and vapor tube assembly quick connect
coupling (part of 9034)
9 W525937 Fuel tank filler pipe hose-to-fuel tank clamp
10 9002 Fuel tank assembly
Rear fuel tank
9057
support strap
12 W506435 Fuel tank support strap bolt (2 required)
13 9A147 Fuel tank skid plate
14 W705047 Fuel tank skid plate nut (4 required)
Fuel Tank and Filler Pipe - Exploded View 3066

15 9054 Front fuel tank support strap

1 - Fuel Tank Pressure (FTP)
sensor and vapor tube
assembly-to-Evaporative
Emission (EVAP) canister
quick connect coupling (part of
9G271)
2 - Fuel tank fuel supply
tube-to-front fuel supply tube
quick connect coupling (part of
9J280)
3 - FTP sensor electrical connector
(part of 14405)
4 - Fuel Pump (FP) module
electrical connector (part of
14405)
5 W705392 Fuel tank filler pipe-to-body
screw (3 required)
6 9034 Fuel tank filler pipe
7 W704901 Fuel tank filler pipe
bracket-to-frame bolts (2
required)
8 >- Fuel tank filler pipe vent
tube-to- FTP sensor and vapor
tube assembly quick connect
106L (28 Gal) Fuel Tank 3067

coupling (part of 9034)

9 W525937 Fuel tank filler pipe
hose-to-fuel tank clamp
10 9002 Fuel tank assembly
11 9057 Rear fuel tank support strap
12 9092 Center fuel tank support strap
13 9054 Front fuel tank support strap
14 W506435 Fuel tank support strap bolt (3
required)
15 9A147 Fuel tank skid plate
16 W705047 Fuel tank skid plate nut (5
required)

Fuel Tank
All fuel tanks
100-02 .
2. Drain the fuel tank. For additional information, refer to Section 310-00 .
106L (28 gal) fuel tank
3. If equipped, remove the 4 nuts and the fuel tank skid plate.
4. If equipped, remove the 5 nuts and the fuel tank skid plate.
All fuel tanks
5. Disconnect the fuel tank filler pipe vent tube-to-Fuel Tank Pressure (FTP) sensor and vapor tube
assembly quick connect coupling in the rear of the fuel tank. For additional information, refer to
Section 310-00 .
Fuel Tank 3069

6. Disconnect the FTP sensor and vapor tube assembly-to-Evaporative Emission (EVAP) canister quick
connect coupling in the front of the fuel tank. For additional information, refer to Section 310-00 .
7. Disconnect the fuel tank fuel supply tube-to-front fuel supply tube quick connect coupling. For
8. Remove the 4 sway bar bracket nuts and let the sway bar hang down.
9. NOTICE: Do not support the fuel tank directly beneath the Fuel Pump (FP) mounting area.
Damage to the FP assembly can occur.
Position a jack under the fuel tank.
10. Remove the center fuel tank support strap bolt.

All fuel tanks
11. Remove the 2 bolts from the front and rear fuel tank support straps.
12. Remove the front fuel tank support strap.
127L (33.5 gal) fuel tanks
13. NOTE: To assist in removing the center fuel tank support strap, the front of the fuel tank may need to
be pushed up slightly to get the center fuel tank support strap to clear the fuel tank.
Lower the fuel tank slightly and rotate the center fuel tank support strap aside.
All fuel tanks
14. Rotate the rear fuel tank support strap aside.
15. Lower the fuel tank slightly. Disconnect the fuel pump module and fuel tank pressure sensor electrical
connectors.
16. Remove the fuel tank from the vehicle.
127L (33.5 gal) fuel tanks
17. If installing a new center fuel tank support strap, remove the center fuel tank support strap from the
vehicle.
Fuel Tank 3070

All fuel tanks
18. If installing a new rear fuel tank support strap, remove the rear fuel tank support strap from the
vehicle.
Fuel Tank 3071

Fuel Tank Filler Pipe
NOTE: The upper fuel tank filler pipe assembly is servicable separatly from the lower fuel tank filler pipe
assembly.
100-02 .
3. Remove the fuel filler door cup bezel. For additional information, refer to Section 501-08 .
4. Remove the 3 fuel tank filler pipe-to-body screws.

5. Disconnect the fuel tank filler pipe vent tube-to-fuel tank pressure sensor and vapor tube assembly
quick connect coupling.
6. Loosen the hose clamp and disconnect the fuel tank filler pipe hose-to-fuel tank.
7. Remove the 2 fuel tank filler pipe support brackets-to-frame bolts.

8. Remove the fuel tank filler pipe assembly.
Fuel Tank Filler Pipe 3072

Fuel Tank Filler Pipe 3073

Fuel Pump Module
Special Tool(s)
Wrench, Fuel Tank Sender Unit

310-123
Part
1 - Fuel supply tube-to-Fuel Pump (FP) module quick
assembly-to- FP module quick connect coupling (part of
9C015)
3 9C385 FP module locking ring
4 9H307 FP pump module
5 9417 FP module O-ring seal
Fuel Pump Module 3074


1 - Fuel Tank Pressure (FTP) sensor and vapor
tube assembly-to-Fuel Pump (FP) module
2 - Fuel supply tube-to- FP module quick
3 - FP module cover nut (3 required)
4 9B007 FP module cover
5 9C385 FP module locking ring
6 9H307 FP pump module
7 9417 FP module O-ring seal
WARNING: Doot carry personal electronic devices such as cell phones, pagers or audio equipment
of any type when working on or near any fuel-related component. Highly flammable mixtures are
always present and may be ignited. Failure to follow these instructions may result in serious personal
injury.
All fuel tanks
1. Remove the fuel tank. For additional information, refer to Fuel Tank in this section.
2. Remove the 3 nuts and the Fuel Pump (FP) module cover.

All fuel tanks
3. Disconnect the Fuel Tank Pressure (FTP) sensor and vapor tube assembly-to- FP module quick
connect coupling and the supply fuel tube-to- FP module quick connect coupling. For additional
4. Using the Fuel Tank Sender Unit Wrench, remove the FP lock ring.
5. NOTICE: Carefully remove the Fuel Pump (FP) assembly to avoid damaging the fuel level
sensor.
NOTE: If the FP does not clear the FP mounting flange on the fuel tank, the use of a screwdriver may
be necessary.
Remove the FP module assembly and FP O-ring seal.
If necessary, insert a screwdriver into the empty FP rod hole and slightly pull the screwdriver
inboard until the base of the FP clears the FP mounting flange.
Discard the FP O-ring seal.


Fuel Lines and Fuel Filter - Exploded View
Part
1 - Evaporative Emission (EVAP) canister-to- EVAP purge
valve quick release coupling (part of 9D676)
2 9G641 EVAP purge valve
3 - Fuel supply tube-to-fuel rail quick connect coupling (part
of 9J280)
4 9F792 Fuel rail
5 - Fuel tank fuel supply tube-to-front fuel supply tube quick
6 - EVAP purge valve-to- EVAP canister quick connect
coupling (part of 9D676)
7 - Fresh air tube-to- EVAP canister quick connect coupling
(part of 2S284)
8 2S284 Fresh air tube
9 9J280 Fuel supply tube
10 9D676 Fuel vapor tube
11 9D319 Fuel supply tube, vapor tube and fresh air tube
bracket-to-transmission housing
12 9D319 Fuel supply tube, vapor tube and fresh air tube
bracket-to-transmission bellhousing
Fuel Lines and Fuel Filter - Exploded View 3078

Fuel Lines and Fuel Filter - Exploded View 3079

Fuel Lines
Removal
100-02 .
2. Release the fuel system pressure. For additional information, refer to Section 310-00 .
3. Disconnect the fuel supply tube-to-fuel rail quick connect coupling. For additional information, refer
to Section 310-00 .
4. Disconnect the Evaporative Emission (EVAP) canister vapor tube-to- EVAP purge valve quick
If equipped, remove the 6 bolts and the transfer case skid plate.
6. If equipped, remove the front driveshaft. For additional information, refer to Section 205-01 .
7. Disconnect the front fuel supply tube-to-fuel tank fuel supply tube quick connect coupling. For
8. Disconnect the EVAP canister vapor tube-to- EVAP canister quick connect coupling and fresh air
tube-to- EVAP canister quick connect coupling. For additional information, refer to Section 310-00 .
Fuel Lines 3080

9. If equipped, remove the selector lever heat shield.
10. Move the locking tab up and disconnect the selector lever cable from the manual lever ball stud.
11. Remove the 2 selector lever bracket bolts and remove the bracket.
12. Remove the front fuel supply tube, fuel vapor tube and fresh air tube pushpin from the bracket at the
transmission bellhousing.
13. Disconnect the LH Heated Oxygen Sensor (HO2S) sensor electrical connector and remove the HO2S
electrical connector wiring pushpin from the fuel supply tube, fuel vapor tube and fresh air tube
bracket at the rear of the transmission housing.
14. NOTE: Front pushpin retainer shown, others similar.
Disconnect the 3 transmission wiring harness pushpin retainers from the bracket at the transmission
bellhousing, the transmission housing and the bracket at the rear of the transmission.
Fuel Lines 3081

15. Remove the fuel supply tube, fuel vapor tube, and fresh air tube from the bracket at the rear of the
transmission housing.
16. Remove the fuel supply tube, fuel vapor tube, and fresh air tube from the vehicle.
Installation
1. Install the fresh air tube into the vehicle and connect the pushpin retainer to the bracket at the
bellhousing and install the line into the bracket at the rear of the transmission.
2. Install the front fuel supply tube into the vehicle and clip it into the bracket at the bellhousing and
install it into the bracket at the rear of the transmission.
3. Install the fuel vapor tube into the vehicle and clip it into the bracket at the bellhousing and install it
into the bracket at the rear of the transmission.
4. NOTE: Front pushpin retainer shown, others similar.
Connect the 3 transmission wiring harness pushpin retainers to the bracket at the transmission
bellhousing, the transmission housing and the bracket at the rear of the transmission.
5. Install the HO2S electrical connector wiring pushpin to the fuel supply tube, fuel vapor tube, and
fresh air tube bracket at the rear of the transmission housing and connect the LH HO2S sensor
6. Install the selector lever bracket and 2 bolts.

are locked in place and the cable end is snapped onto the ball stud. Press the selector lever cable into
the bracket and listen for the cable to click into place. Pull back on the selector lever cable to make
sure that it is locked in the bracket. Also, make sure that the selector lever cable end is correctly
Fuel Lines 3082

installed onto the ball stud. Pull back on the selector lever cable to make sure that the cable end is
correctly installed.
With the manual lever in NEUTRAL, connect the selector lever cable onto the manual lever ball stud
and move the locking tab downward into the locked position.

Pull back on the selector lever cable to make sure it is correctly installed.
8. If equipped, install the selector lever heat shield.
9. Connect the EVAP canister vapor tube-to- EVAP canister quick connect coupling and fresh air
tube-to- EVAP canister quick connect coupling. For additional information, refer to Section 310-00 .
10. Connect the front fuel supply tube-to-fuel tank fuel supply tube quick connect coupling. For
11. If equipped, install the front driveshaft. For additional information, refer to Section 205-01 .
13. Connect the fuel supply tube-to-fuel rail quick connect coupling. For additional information, refer to
Section 310-00 .
14. Connect the EVAP canister fuel vapor tube-to- EVAP purge valve quick connect coupling. For
Fuel Lines 3083

Fuel Lines 3084

Fuel Filter
1. The fuel tank(s) has a fuel filter that is part of the Fuel Pump (FP) module and cannot be serviced
separately from the FP module. For additional information, refer to Fuel Pump Module in this section.
Fuel Filter 3085

Inertia Fuel Shutoff (IFS) Switch
Part
1 312A29 Access cover
2 - Inertia Fuel Shutoff (IFS) switch electrical connector
(part of 180103)
3 N611043 IFS bolts (2 required)
4 9341 IFS switch
5 - Power liftgate motor electrical connector (part of
404C85)
6 - Power liftgate motor electrical connector (part of
404C85)
1. NOTE: The Inertia Fuel Shutoff (IFS) switch is located behind the LH quarter trim panel access
cover.
Remove the LH quarter trim panel access cover.
2. Remove the power liftgate motor electrical connector pushpins from the power liftgate motor bracket.
3. NOTE: Slide the IFS switch out below the power liftgate motor bracket.
Remove the 2 bolts and the IFS switch.
4. Disconnect the IFS switch electrical connector.
Inertia Fuel Shutoff (IFS) Switch 3086


SECTION 310-02: Acceleration Control 2011 Expedition, Navigator Workshop Manual

Adjustable accelerator pedal bolts 25 18
Fixed accelerator pedal bolts 25 18


Acceleration Control
The acceleration control consists of one of the following:
A fixed accelerator pedal and position sensor assembly

An adjustable accelerator pedal and position sensor assembly
The throttle is controlled by an Accelerator Pedal Position (APP) sensor on the accelerator pedal assembly.
The APP sensor sends a signal to the PCM in response to throttle pedal movements initiated by the driver.
The PCM sends a signal to the electronic throttle control which increases and decreases throttle position.
Some vehicles are equipped with adjustable pedals. This allows both the accelerator and brake pedals to be
adjusted simultaneously forward or rearward. A rocker switch on the instrument panel provides adjustment on
the pedal assembly when it is activated. On vehicles with the memory seat option, the pedal position can be
controlled by the memory selection, as well as the rocker switch. The components in the acceleration control
system cannot be repaired, new components must be installed if damaged or worn. When servicing the
adjustable accelerator pedal, always disconnect the cable at the brake pedal.
Acceleration Control 3089


Acceleration Control
Acceleration Control 3090


Accelerator Pedal - Fixed

1 - Accelerator Pedal Position (APP) sensor
electrical connector (part of 12A581)
2 W713384 Accelerator pedal assembly bolts (3 required)
3 9F836 Accelerator pedal assembly
1. Disconnect the Accelerator Pedal Position (APP) sensor electrical connector.
2. Remove the 3 bolts and the accelerator pedal assembly.

Accelerator Pedal - Fixed 3091

Accelerator Pedal - Fixed 3092


Accelerator Pedal - Adjustable
Part
1 - Accelerator pedal-to-brake pedal cable (part of 9F836)
2 - Accelerator Pedal Position (APP) sensor electrical
connector (part of 12A581)
3 - APP sensor electrical connector wiring harness retainer
(part of 12A581)
4 9F836 Accelerator pedal assembly
5 W713384 Accelerator pedal assembly bolts (3 required)
NOTE: The brake pedal and the accelerator pedal must be in the same position when installing a new cable or
a new pedal. The pedals must be in the all the way forward position.
1. NOTE: To prevent setting DTCs, make sure the ignition switch is in the OFF position prior to
disconnecting the accelerator pedal electrical connector.
Disconnect the Accelerator Pedal Position (APP) sensor electrical connector.
2. Disconnect the accelerator pedal-to-brake pedal cable from the brake pedal.
3. Remove the 3 bolts and the accelerator pedal assembly.ype="disc">

4. To install, tighten to 25 Nm (18 lb-ft).
Accelerator Pedal - Adjustable 3093

Accelerator Pedal - Adjustable 3094

Acronyms
2WD - 2-Wheel Drive
4WD - Four-Wheel Drive
ABS - Acrylonitrile Butadiene Styrene
ABS - Anti-Lock Brake System
ACL - Air Cleaner
ACM - Audio Control Module
ACM - Audio Front Control Module
ACMs - Audio Control Modules
ALR - Automatic Locking Retractor
APIM - Accessory Protocol Interface Module
APP - Accelerator Pedal Position
ASE - Automotive Service Excellence
ATC - Automatic Traction Control
AWD - All-Wheel Drive
BCM - Body Control Module
BH - Bake Hardened Steel
BJB - Battery Junction Box
BLISTM - Blind Spot Information System
BPP - Brake Pedal Position
BSIA - Brake Shift Interlock Actuator
BTDC - Before Top Dead Center
CAN - Controller Area Network
CASS - Compressor Anti-Slugging Strategy
CHT - Cylinder Head Temperature
CIP - Consumer Interface Processor
CJB - Central Junction Box
Acronyms 3095
CKP - Crankshaft Position
CMDTC - Continuous Memory Diagnostic Trouble Code
CMDTCs - Continuous Memory Diagnostic Trouble Codes
CMP - Camshaft Position
CMS - Catalyst Monitor Sensor
CPA - Connector Position Assurance
CTA - Cross Traffic Alert
D/A - Dual Action
DATC - Dual Automatic Temperature Control
DCSM - Dual Climate Controlled Seat Module
DERU - Drive Engine Run-Up
DLC - Data Link Connector
DMM - Digital Multimeter
DRL - Daytime Running Lamps
DRM - Digital Rights Management
DSM - Driver Seat Module
DSO - District Special Order
DSP - Digital Signal Processing
DTC - Diagnostic Trouble Code
DTE - Distance To Empty
EATC - Electronic Automatic Temperature Control
EBD - Electronic Brake Distribution
ECM - Engine Control Module
ECT - Engine Coolant Temperature
ECU - Electronic Control Unit
EEPROM - Electrically Erasable Programmable Read-Only Memory
EI - Electronic Ignition
Acronyms 3096
ELR - Emergency Locking Retractor
EMTC - Electronic Manual Temperature Control
EONV - Engine Off Natural Vacuum
EOP - Engine Oil Pressure
EOT - Engine Oil Temperature
EPC - Electronic Pressure Control
ERFS - Electronic Returnless Fuel System
ESC - Electronic Stability Control
ESN - Electronic Serial Number
ETB - Electronic Throttle Body
ETC - Electronic Throttle Control
EVA - Electronic Vibration Analyzer
EVAP - Evaporative Emission
FCIM - Front Controls Interface Module
FDIM - Front Display Interface Module
FEAD - Front End Accessory Drive
FESM - Front End Sheet Metal
FET - Field-Effect Transistor
FFV - Flexible Fuel Vehicle
FIA - Factory Invoiced Accessory
FICM - Fuel Injection Control Module
FP - Fuel Pump
FTP - Fuel Tank Pressure
FWD - Front Wheel Drive
GEM - Generic Electronic Module
GPS - Global Positioning System
GPSM - Global Positioning System Module
Acronyms 3097
GVWR - Gross Vehicle Weight Rating
HCM-2 - Headlamp Control Module 2
HCU - Hydraulic Control Unit
HID - High Intensity Discharge
HO2S - Heated Oxygen Sensor
HS-CAN - High Speed Controller Area Network
HSLA - High-Strength Low Alloy
HVAC - Heating Ventilation Air Conditioning
IAT - Intake Air Temperature
IC - Instrument Cluster
IDS - Integrated Diagnostic System
IFS - Inertia Fuel Shutoff
IKT - Integrated Keyhead Transmitter
IKTs - Integrated Keyhead Transmitters
IPC - Instrument Panel Cluster
IPM-A - Image Processing Module - A
IWE - Integrated Wheel End
IWEs - Integrated Wheel Ends
KAM - Keep Alive Memory
KOEO - Key ON Engine OFF
KOER - Key ON Engine Running
KS - Knock Sensor
LED - Light Emitting Diode
LH - Left Hand
LPC - Line Pressure Control
LTM - Liftgate/Trunk Module
MACS - Mobile Air Conditioning Society
Acronyms 3098
MAF - Mass Air Flow
MAP - Manifold Absolute Pressure
MFI - Multi-Port Fuel Injection
MIG - Metal Inert Gas
MIL - Malfunction Indicator Lamp
MPV - Multi-Purpose Vehicle
MRFS - Mechanical Returnless Fuel System
MS-CAN - Medium Speed Controller Area Network
MSS - Mode Select Switch
NERU - Neutral Engine Run-Up
NVM - Non-Volatile Memory
O/D - Overdrive
OASIS - On-Line Automotive Service Information System
OBD - On-Board Diagnostic
OCS - Occupant Classification System
OCSM - Occupant Classification System Module
ORVR - On-Board Refueling Vapor Recovery
OSS - Output Shaft Speed
OTIS - One-Touch Integrated Start
OWC - One-Way Clutch
PAM - Parking Aid Module
PATS - Passive Anti-Theft System
PC - Polycarbonate
PC/ED - Powertrain Control/Emissions Diagnosis
PCA - Pressure Control Solenoid A
PDB - Power Distribution Box
PIN - Personal Identification Number
Acronyms 3099
PMI - Programmable Module Installation
PNP - Park/Neutral Position
PRB - Power Running Board
PRBs - Power Running Boards
PSP - Power Steering Pressure
PVC - Polyvinyl Chloride
PWM - Pulse Width Modulated
PWM - Pulse-Width Modulation
RAM - Random Access Memory
RCM - Restraints Control Module
RCU - Rear Control Unit
READ - Rear End Accessory Drive
RETM - Rear Entertainment Module
RFI - Radio Frequency Interference
RKE - Remote Keyless Entry
ROM - Read-Only Memory
ROW - Rest Of World
RSC - Roll Stability Control
RWD - Rear Wheel Drive
SCP - Standard Corporate Protocol
SDARS - Satellite Digital Audio Receiver System
SFI - Sequential Multi-Port Fuel Injection
SJB - Smart Junction Box
SMC - Sheet-Molded Composite
SRS - Supplemental Restraint System
SSA - Shift Solenoid A
SSB - Shift Solenoid B
Acronyms 3100
SSC - Shift Solenoid C
SSD - Shift Solenoid D
SSE - Shift Solenoid E
SSPCA - Shift Solenoid Pressure Control A
SSPCB - Shift Solenoid Pressure Control B
SSPCC - Shift Solenoid Pressure Control C
SSPCD - Shift Solenoid Pressure Control D
SSPCE - Shift Solenoid Pressure Control E
STRW - Squeeze-Type Resistance Spot Welding
TB - Throttle Body
TBC - Trailer Brake Control
CC - Torque Converter Clutch
TCCM - Transfer Case Control Module
TCIL - Transmission Control Indicator Lamp
TCM - Transmission Control Module
TED - Thermo-Electric Device
TEDs - Thermo-Electric Devices
TFT - Transmission Fluid Temperature
TIC - Transmitter Identification Code
TICs - Transmitter Identification Codes
TP - Throttle Position
TPM - Tire Pressure Monitor
TPMS - Tire Pressure Monitoring System
TPO - Thermoplastic Olefin
TR - Transmission Range
TSB - Technical Service Bulletin
TSS - Turbine Shaft Speed
Acronyms 3101
TTS - Text-To-Speech
TXV - Thermostatic Expansion Valve
UHSS - Ultra High Strength Steel
USB - Universal Serial Bus
VC - Vehicle Certification
VCM - Vehicle Communication Module
VCT - Variable Camshaft Timing
VDM - Vehicle Dynamics Module
VF - Vacuum Fluorescent
VFS - Variable Force Solenoid
VID - Vehicle Identification
VIL - Vehicle Identification Label
VIN - Vehicle Identification Number
VIP - Vehicle Interface Processor
VSS - Vehicle Speed Sensor
WMI - World Manufacturer Identifier
WOT - Wide Open Throttle
Acronyms 3102
Alphabetical Index
4|A|B|C|D|E|F|G|H|I|J|K|L|M|N|O|P|Q|R|S|T|U|V|W
4
4X4 Control Module (REMOVAL AND INSTALLATION, Four Wheel Drive (4WD) Systems)
A
A-Pillar Trim Panel (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Acceleration Control (DESCRIPTION AND OPERATION)
Acceleration Control (DIAGNOSIS AND TESTING)
Acceleration Control (Section Table of Contents)
Acceleration Control (SPECIFICATIONS)
Accelerator Pedal - Adjustable (REMOVAL AND INSTALLATION, Acceleration Control)
Accelerator Pedal - Fixed (REMOVAL AND INSTALLATION, Acceleration Control)
Accessory Drive (DESCRIPTION AND OPERATION)
Accessory Drive (DIAGNOSIS AND TESTING)
Accessory Drive (Section Table of Contents)
Accessory Drive (SPECIFICATIONS)
Accessory Drive Belt (REMOVAL AND INSTALLATION, Accessory Drive)
Accessory Drive Belt Idler Pulley (REMOVAL AND INSTALLATION, Accessory Drive)
Accessory Drive Belt Tensioner (REMOVAL AND INSTALLATION, Accessory Drive)
Accessory Protocol Interface Module (APIM) (REMOVAL AND INSTALLATION, Information and
Entertainment Systems)
Accessory Protocol Interface Module (APIM) Programming (GENERAL PROCEDURES, Module

Configuration)
Accessory Protocol Interface Module (APIM) Software Level Check (GENERAL PROCEDURES,
Information and Entertainment Systems)
Adhesives (DESCRIPTION AND OPERATION, Body Repairs)
Alphabetical Index 3103

Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) (DESCRIPTION AND
OPERATION, Supplemental Restraint System)
Air Bag and Safety Belt Pretensioner Supplemental Restraint System (SRS) (DIAGNOSIS AND TESTING,
Supplemental Restraint System)
Air Bag Trim Cover - Passenger (REMOVAL AND INSTALLATION, Supplemental Restraint System)
Air Cleaner (REMOVAL AND INSTALLATION, Intake Air Distribution and Filtering)
Air Cleaner Element (REMOVAL AND INSTALLATION, Intake Air Distribution and Filtering)
Air Cleaner Outlet Pipe (REMOVAL AND INSTALLATION, Intake Air Distribution and Filtering)
Air Conditioning (DESCRIPTION AND OPERATION, Climate Control)
Air Conditioning (A/C) Clutch Air Gap Adjustment (GENERAL PROCEDURES, Climate Control System -
General Information and Diagnostics)
Air Conditioning (A/C) Compressor (REMOVAL AND INSTALLATION, Climate Control)
Air Conditioning (A/C) Odor Treatment (GENERAL PROCEDURES, Climate Control System - General
Information and Diagnostics)
Air Conditioning (A/C) Pressure Relief Valve (REMOVAL AND INSTALLATION, Climate Control)
Air Conditioning (A/C) System Recovery, Evacuation and Charging (GENERAL PROCEDURES, Climate
Control System - General Information and Diagnostics)
Air Deflector (REMOVAL AND INSTALLATION, Roof Opening Panel)
Air Distribution and Filtering (DESCRIPTION AND OPERATION, Climate Control)
Air Leaks (GENERAL PROCEDURES, Vehicle Dynamic Suspension)
Air Line Fluid Purge (GENERAL PROCEDURES, Vehicle Dynamic Suspension)
Air Shock Absorber - Rear (REMOVAL AND INSTALLATION, Vehicle Dynamic Suspension)
Air Spring Inflation and Deflation (GENERAL PROCEDURES, Vehicle Dynamic Suspension)
Air Spring Solenoid Valve (REMOVAL AND INSTALLATION, Vehicle Dynamic Suspension)
Air Suspension Compressor (REMOVAL AND INSTALLATION, Vehicle Dynamic Suspension)
Air Suspension Compressor Drier (REMOVAL AND INSTALLATION, Vehicle Dynamic Suspension)
Air Suspension System Disable/Enable (GENERAL PROCEDURES, Vehicle Dynamic Suspension)
Alternating Current (AC) Powerpoint (REMOVAL AND INSTALLATION, High Voltage

Converter/Inverter)
Ambient Air Temperature Sensor (REMOVAL AND INSTALLATION, Climate Control)
A 3104
Antenna Cable - AM/FM (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Antenna Cable - Satellite Radio (REMOVAL AND INSTALLATION, Information and Entertainment
Systems)
Antenna Isolator Module (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Antenna - Satellite Radio (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Anti-Lock Brake System (ABS) and Stability Control (Section Table of Contents)
Anti-Lock Brake System (ABS) and Stability Control (SPECIFICATIONS)
Anti-Lock Brake System (ABS) Module (REMOVAAND INSTALLATION, Anti-Lock Brake System (ABS)
and Stability Control)
Anti-Lock Control (DESCRIPTION AND OPERATION, Anti-Lock Brake System (ABS) and Stability
Control)
Anti-Lock Control (DIAGNOSIS AND TESTING, Anti-Lock Brake System (ABS) and Stability Control)
Anti-Theft (DESCRIPTION AND OPERATION, Anti-Theft - Passive Anti-Theft System (PATS))
Anti-Theft (DESCRIPTION AND OPERATION, Anti-Theft - Perimeter)
Anti-Theft (DIAGNOSIS AND TESTING, Anti-Theft - Passive Anti-Theft System (PATS))
Anti-Theft (DIAGNOSIS AND TESTING, Anti-Theft - Perimeter)
Anti-Theft Security Access (GENERAL PROCEDURES, Anti-Theft - Passive Anti-Theft System (PATS))
Anti-Theft - Passive Anti-Theft System (PATS) (Section Table of Contents)
Anti-Theft - Perimeter (Section Table of Contents)
Audio Amplifier (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Audio Control Module (ACM) (REMOVAL AND INSTALLATION, Information and Entertainment
Systems)
Audio Control Module (ACM) Self-Diagnostic Mode (GENERAL PROCEDURES, Information and
Audio Digital Signal Processing (DSP) Module (REMOVAL AND INSTALLATION, Information and
Audio Input Jack (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Audio Rear Control Unit (RCU) Module (REMOVAL AND INSTALLATION, Information and
Autolamps (DIAGNOSIS AND TESTING, Exterior Lighting)
Autolamps Time Delay Adjustment (GENERAL PROCEDURES, Exterior Lighting)
A 3105
Autolock and Auto-Unlock Programming (GENERAL PROCEDURES, Handles, Locks, Latches and Entry
Systems)
Automatic Transaxle/Transmission External Controls (Section Table of Contents)
Automatic Transaxle/Transmission External Controls (SPECIFICATIONS)
Automatic Transaxle/Transmission - 6R80 (Section Table of Contents)
Automatic Transaxle/Transmission - 6R80 (SPECIFICATIONS)
Auxiliary Blower Motor (REMOVAL AND INSTALLATION, Auxiliary Climate Control)
Auxiliary Blower Motor ResistREMOVAL AND INSTALLATION, Auxiliary Climate Control)
Auxiliary Climate Control (DESCRIPTION AND OPERATION)
Auxiliary Climate Control (Section Table of Contents)
Auxiliary Climate Control (SPECIFICATIONS)
Auxiliary Climate Control Assembly (REMOVAL AND INSTALLATION, Auxiliary Climate Control)
Auxiliary Evaporator Core (REMOVAL AND INSTALLATION, Auxiliary Climate Control)
Auxiliary Evaporator Outlet and Inlet Line (REMOVAL AND INSTALLATION, Auxiliary Climate Control)
Auxiliary Heater Core and Evaporator Core Housing - Expedition EL, Navigator L (REMOVAL AND
INSTALLATION, Auxiliary Climate Control)
Auxiliary Heater Core and Evaporator Core Housing - Expedition, Navigator (REMOVAL AND
INSTALLATION, Auxiliary Climate Control)
Auxiliary Heater Core - Expedition EL, Navigator L (REMOVAL AND INSTALLATION, Auxiliary Climate
Control)
Auxiliary Heater Core - Expedition, Navigator (REMOVAL AND INSTALLATION, Auxiliary Climate
Control)
Auxiliary Heater Outlet and Inlet Line (REMOVAL AND INSTALLATION, Auxiliary Climate Control)
Auxiliary Mode Door Actuator - Expedition EL, Navigator L (REMOVAL AND INSTALLATION,
Auxiliary Climate Control)
Auxiliary Mode Door Actuator - Expedition, Navigator (REMOVAL AND INSTALLATION, Auxiliary
Climate Control)
Auxiliary Temperature Blend Door Actuator - Expedition EL, NavigatMOVAL AND INSTALLATION,
Auxiliary Temperature Blend Door Actuator - Expedition, Navigator (REMOVAL AND INSTALLATION,
Auxiliary Transmission Fluid Cooler (REMOVAL AND INSTALLATION, Transaxle/Transmission Cooling)
A 3106
Axle (DISASSEMBLY AND ASSEMBLY, Front Drive Axle/Differential)
Axle (DISASSEMBLY AND ASSEMBLY, Rear Drive Axle/Differential - Ford 9.75-Inch Ring Gear)
Axle Assembly (REMOVAL AND INSTALLATION, Front Drive Axle/Differential)
Axle Assembly (REMOVAL AND INSTALLATION, Rear Drive Axle/Differential - Ford 9.75-Inch Ring
Gear)
Axle Carrier Bushing (REMOVAL AND INSTALLATION, Front Drive Axle/Differential)
Azimuth System Check (GENERAL PROCEDURES, Parking Aid)
B
B-Pillar Trim Panel (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Ball Joint - Lower (REMOVAL AND INSTALLATION, Front Suspension - Four Wheel Drive (4WD))
Ball Joint - Lower (REMOVAL AND INSTALLATION, Front Suspension - Rear Wheel Drive (RWD))
Ball Joint - Lower (REMOVAL AND INSTALLATION, Rear Suspension)
Ballast (REMOVAL AND INSTALLATION, Exterior Lighting)
Battery (REMOVAL AND INSTALLATION, Battery, Mounting and Cables)
Battery and Battery Tray - Exploded View (REMOVAL AND INSTALLATION, Battery, Mounting and
Cables)
Battery and Cables (DESCRIPTION AND OPERATION, Battery, Mounting and Cables)
Battery Cables (REMOVAL AND INSTALLATION, Battery, Mounting and Cables)
Battery Disconnect (GENERAL PROCEDURES, Battery, Mounting and Cables)
Battery Tray (REMOVAL AND INSTALLATION, Battery, Mounting and Cables)
Battery, Mounting and Cables (Section Table of Contents)
Battery, Mounting and Cables (SPECIFICATIONS)
Bearing Inspection (GENERAL PROCEDURES, Engine System - General Information)
Belt-Minder Deactivating/Activating (GENERAL PROCEDURES, Instrumentation, Message Center, and

Warning Chimes)
Block Heater (REMOVAL AND INSTALLATION, Engine Cooling)
Blower Motor (REMOVAL AND INSTALLATION, Climate Control)
Blower Motor Resistor (REMOVAL AND INSTALLATION, Climate Control)
B 3107
Blower Motor Speed Control (REMOVAL AND INSTALLATION, Climate Control)
Body (DESCRIPTION AND OPERATION, Body Repairs)
Body (REMOVAL AND INSTALLATION, Full Frame and Body Mounting)
Body Closures (DESCRIPTION AND OPERATION)
Body Closures (Section Table of Contents)
Body Closures (SPECIFICATIONS)
Body Repairs (Section Table of Contents)
Body Repairs (SPECIFICATIONS)
Body Sealer Types And Applications (DESCRIPTION AND OPERATION, Body System - General
Information)
Body System (DIAGNOSIS AND TESTING, Body System - General Information)
Body System - General Information (Section Table of Contents)
Body System - General Information (SPECIFICATIONS)
Brake Booster (DESCRIPTION AND OPERATION, Power Brake Actuation)
Brake Booster (REMOVAL AND INSTALLATION, Power Brake Actuation)
Brake Booster Vacuum Sensor (REMOVAL AND INSTALLATION, Power Brake Actuation)
Brake Caliper (REMOVAL AND INSTALLATION, Front Disc Brake)
Brake Caliper (REMOVAL AND INSTALLATION, Rear Disc Brake)
Brake Caliper Anchor Plate (REMOVAL AND INSTALLATION, Front Disc Brake)
Brake Caliper Anchor Plate (REMOVAL AND INSTALLATION, Rear Disc Brake)
Brake Disc (REMOVAL AND INSTALLATION, Front Disc Brake)
Brake Disc (REMOVAL AND INSTALLATION, Rear Disc Brake)
Brake Disc Machining (GENERAL PROCEDURES, Brake System - General Information)
Brake Disc Shield (REMOVAL AND INSTALLATION, Front Disc Brake)
Brake Flexible Hose (REMOVAL AND INSTALLATION, Front Disc Brake)
Brake Flexible Hose (REMOVAL AND INSTALLATION, Rear Disc Brake)
Brake Master Cylinder (REMOVAL AND INSTALLATION, Hydraulic Brake Actuation)
Brake Pads (REMOVAL AND INSTALLATION, Front Disc Brake)
B 3108
Brake Pads (REMOVAL AND INSTALLATION, Rear Disc Brake)
Brake Pedal and Bracket (REMOVAL AND INSTALLATION, Hydraulic Brake Actuation)
Brake Shift Interlock Actuator - Column Shift (REMOVAL AND INSTALLATION, Automatic
Transaxle/Transmission External Controls)
Brake Shift Interlock Actuator - Floor Shift (REMOVAL AND INSTALLATION, Automatic
Brake Shift Interlock Override - Column Shift (GENERAL PROCEDURES, Automatic

Brake Shift Interlock Override - Floor ShifAL PROCEDURES, Automatic Transaxle/Transmission External
Controls)
Brake System (DESCRIPTION AND OPERATION, Brake System - General Information)
Brake System Bleeding (GENERAL PROCEDURES, Brake System - General Information)
Brake System Inspection (GENERAL PROCEDURES, Brake System - General Information)
Brake System - General Information (Section Table of Contents)
Brake System - General Information (SPECIFICATIONS)
Bumper Cover - Front (REMOVAL AND INSTALLATION, Bumpers)
Bumper Cover - Rear (REMOVAL AND INSTALLATION, Bumpers)
Bumper - Exploded View, Front (REMOVAL AND INSTALLATION, Bumpers)
Bumper - Exploded View, Rear (REMOVAL AND INSTALLATION, Bumpers)
Bumper - Front (REMOVAL AND INSTALLATION, Bumpers)
Bumpers (Section Table of Contents)
Bumpers (SPECIFICATIONS)
C
C-Pillar Trim Panel (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Camber Adjustment - Rear (GENERAL PROCEDURES, Suspension System - General Information)
Camber and Caster Adjustment - Front (GENERAL PROCEDURES, Suspension System - General
Information)
Camshaft Bearing Journal Diameter (GENERAL PROCEDURES, Engine System - General Information)
Camshaft End Play - OHC Engines (GENERAL PROCEDURES, Engine System - General Information)
C 3109
Camshaft Journal to Bearing Clearance - OHC Engines (GENERAL PROCEDURES, Engine System -
General Information)
Camshaft Lobe Lift (GENERAL PROCEDURES, Engine System - General Information)
Camshaft Phaser and Sprocket Inspection (GENERAL PROCEDURES, Engine System - General
Information)
Camshaft Phaser and Sprocket - LH (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Camshaft Phaser and Sprocket - RH (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Camshaft Position (CMP) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls)
Camshaft Roller Follower (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Camshaft Runout (GENERAL PROCEDURES, Engine System - General Information)
Camshaft Surface Inspection (GENERAL PROCEDURES, Engine System - General Information)
Camshaft - LH (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Camshaft - RH (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Cargo Lamp (REMOVAL AND INSTALLATION, Interior Lighting)
Catalyst Monitor Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls)
Charging System (DESCRIPTION AND OPERATION)
Charging System (Section Table of Contents)
Charging System (SPECIFICATIONS)
Child Safety Seat Tether Anchor (REMOVAL AND INSTALLATION, Safety Belt System)
Climate Control (Section Table of Contents)
Climate Control (SPECIFICATIONS)
Climate Control System (DESCRIPTION AND OPERATION, Climate Control System - General
Information and Diagnostics)
Climate Control System (DIAGNOSIS AND TESTING, Climate Control System - General Information and
Diagnostics)
Climate Control System - General Information and Diagnostics (Section Table of Contents)
Climate Control System - General Information and Diagnostics (SPECIFICATIONS)
Clock (DESCRIPTION AND OPERATION)
Clock (DIAGNOSIS AND TESTING)
C 3110
Clock (REMOVAL AND INSTALLATION)
Clock (Section Table of Contents)
Clockspring (REMOVAL AND INSTALLATION, Supplemental Restraint System)
Clutch and Clutch Field Coil (REMOVAL AND INSTALLATION, Climate Control)
Communications Network (DESCRIPTION AND OPERATION, Module Communications Network)
Communications Network (DIAGNOSIS AND TESTING, Module Communications Network)
Compass Calibration - With Message Center (GENERAL PROCEDURES, Instrumentation, Message Center,
and Warning Chimes)
Compass Calibration - Without Message Center (GENERAL PROCEDURES, Instrumentation, Message

Center, and Warning Chimes)
Compass Zone Adjustment - With Message Center (GENERAL PROCEDURES, Instrumentation, Message
Center, and Warning Chimes)
Compass Zone Adjustment - Without Message Center (GENERAL PROCEDURES, Instrumentation,

Message Center, and Warning Chimes)
Component Bleeding (GENERAL PROCEDURES, Brake System - General Information)
Component Test (DIAGNOSIS AND TESTING, Battery, Mounting and Cables)
Component Tests (DIAGNOSIS AND TESTING, Brake System - General Information)
Compressor to Condenser Discharge Line (REMOVAL AND INSTALLATION, Climate Control)
Condenser Core (REMOVAL AND INSTALLATION, Climate Control)
Connecting Rod Bearing Journal Taper and Out-of-Round (GENERAL PROCEDURES, Engine System -
Connecting Rod Bearing Journal-to-Bearing Clearance (GENERAL PROCEDURES, Engine System -

Connecting Rod Bend (GENERAL PROCEDURES, Engine System - General Information)
Connecting Rod Bushing Diameter (GENERAL PROCEDURES, Engine System - General Information)
Connecting Rod Cleaning (GENERAL PROCEDURES, Engine System - General Information)
Connecting Rod Large End Bore (GENERAL PROCEDURES, Engine System - General Information)
Connecting Rod to Crankshaft Side Clearance (GENERAL PROCEDURES, Engine System - General
Information)
Connecting Rod Twist (GENERAL PROCEDURES, Engine System - General Information)
Console - Front, Floor, Expedition (REMOVAL AND INSTALLATION, Instrument Panel and Console)
C 3111
Console - Front, Floor, Navigator (REMOVAL AND INSTALLATION, Instrument Panel and Console)
Console - Overhead (REMOVAL AND INSTALLATION, Instrument Panel and Console)
Console - Rear, Floor (REMOVAL AND INSTALLATION, Instrument Panel and Console)
Control Components (DESCRIPTION AND OPERATION, Climate Control)
Coolant Crossover Manifold Assembly (REMOVAL AND INSTALLATION, Engine Cooling)
Coolant Expansion Tank (REMOVAL AND INSTALLATION, Engine Cooling)
Coolant Pump (REMOVAL AND INSTALLATION, Engine Cooling)
Cooling Fan Motor and Shroud (REMOVAL AND INSTALLATION, Engine Cooling)
Cooling Module (REMOVAL AND INSTALLATION, Engine Cooling)
Cooling System Draining, Filling and Bleeding (GENERAL PROCEDURES, Engine Cooling)
Cooling System Flushing (GENERAL PROCEDURES, Engine Cooling)
Core Plug Replacement (GENERAL PROCEDURES, Engine System - General Infoation)
Cowl Panel Grille (REMOVAL AND INSTALLATION, Front End Body Panels)
Crankshaft End Play (GENERAL PROCEDURES, Engine System - General Information)
Crankshaft Front Seal (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Crankshaft Main Bearing Journal Diameter (GENERAL PROCEDURES, Engine System - General
Information)
Crankshan Bearing Journal Taper and Out-of-Round (GENERAL PROCEDURES, Engine System - General
Information)
Crankshaft Main Bearing Journal-to-Bearing Clearance (GENERAL PROCEDURES, Engine System -

Crankshaft Position (CKP) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls)
Crankshaft Pulley (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Crankshaft Rear Seal (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Crankshaft Rear Seal with Retainer Plate (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Cruise Control (DESCRIPTION AND OPERATION)
Cruise Control (DIAGNOSIS AND TESTING)
Cruise Control (Section Table of Contents)
Cruise Control Switch (REMOVAL AND INSTALLATION, Cruise Control)
C 3112
Cylinder Block Distortion (GENERAL PROCEDURES, Engine System - General Information)
Cylinder Bore Cleaning (GENERAL PROCEDURES, Engine System - General Information)
Cylinder Bore Out-of-Round (GENERAL PROCEDURES, Engine System - General Information)
Cylinder Bore Taper (GENERAL PROCEDURES, Engine System - General Information)
Cylinder Head (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Engine - 5.4L (3V))
Cylinder Head (INSTALLATION, Engine - 5.4L (3V))
Cylinder Head (REMOVAL, Engine - 5.4L (3V))
Cylinder Head Distortion (GENERAL PROCEDURES, Engine System - General Information)
Cylinder Head Temperature (CHT) Sensor (REMOVAL AND INSTALLATION, Electronic Engine
Controls)
D
D-Pillar Trim Panel (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Daytime Running Lamps (DRL) (DIAGNOSIS AND TESTING, Exterior Lighting)
Diagnosis By Symptom (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6R80)
Diagnostic Flow Chart (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6R80)
Diagnostic Methods (DESCRIPTION AND OPERATION, Service Information)
Diagnostic Parameters Identification (PID) Chart (DIAGNOSIS AND TESTING, Automatic

Transaxle/Transmission - 6R80)
Diagnostic Strategy (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6R80)
Diagnostic Trouble Code (DTC) Chart (DIAGNOSIS AND TESTING, Charging System)
Diagnostic Trouble Code (DTC) Chart (DIAGNOSIS AND TESTING, Exterior Lighting)
Diagnostic Trouble Code (DTC) Chart (DIAGNOSIS AND TESTING, Multifunction Electronic Modules)
Diagnostic Trouble Code (DTC) Charts (DIAGSIS AND TESTING, Automatic Transaxle/Transmission -
6R80)
Diagnostic Trouble Code (DTC) Charts (DIAGNOSIS AND TESTING, Hydraulic Brake Actuation)
Diagnostics (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6R80)
Differential Bearings (REMOVAL AND INSTALLATION, Front Drive Axle/Differential)
D 3113
Differential Bearings (REMOVAL AND INSTALLATION, Rear Drive Axle/Differential - Ford 9.75-Inch
Ring Gear)
Differential Carrier (REMOVAL AND INSTALLATION, Front Drive Axle/Differential)
Differential Case (DISASSEMBLY AND ASSEMBLY, Front Drive Axle/Differential)
Differential Case Runout Check (GENERAL PROCEDURES, Front Drive Axle/Differential)
Differential Ring And Pinion (REMOVAL AND INSTALLATION, Front Drive Axle/Differential)
Differential Ring And Pinion (REMOVAL AND INSTALLATION, Rear Drive Axle/Differential - Ford
9.75-Inch Ring Gear)
Direct Clutch Assembly (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Automatic

Direct Current/Alternating Current (DC/AC) Inverter (REMOVAL AND INSTALLATION, High Voltage
Converter/Inverter)
Disc Brake System - Exploded View (REMOVAL AND INSTALLATION, Front Disc Brake)
Disc Brake System - Exploded View (REMOVAL AND INSTALLATION, Rear Disc Brake)
Door (REMOVAL AND INSTALLATION, Body Closures)
Door Ajar Switch (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry Systems)
Door Alignment - Front (GENERAL PROCEDURES, Body Closures)
Door Alignment - Rear (GENERAL PROCEDURES, Body Closures)
Door Check Arm (REMOVAL AND INSTALLATION, Body Closures)
Door Glass Top Run - Front (REMOVAL AND INSTALLATION, Glass, Frames and Mechanisms)
Door Glass Top Run - Rear (REMOVAL AND INSTALLATION, Glass, Frames and Mechanisms)
Door Handle to Latch Rod Adjustment (GENERAL PROCEDURES, Handles, Locks, Latches and Entry
Systems)
Door Lock Actuator (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry Systems)
Door Lock Cylinder (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry Systems)
Door ter Panel (REMOVAL AND INSTALLATION, Body Repairs)
Door Trim Panel - Front (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Door Trim Panel - Rear (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Drive Pinion Flange and Drive Pinion Seal (IN-VEHICLE REPAIR, Rear Drive Axle/Differential - Ford
D 3114
Drive Pinion Flange and Seal (IN-VEHICLE REPAIR, Front Drive Axle/Differential)
Driveline Angle Measurement (GENERAL PROCEDURES, Driveline System - General Information)
Driveline System (DESCRIPTION AND OPERATION, Driveline System - General Information)
Driveline System (DIAGNOSIS AND TESTING, Driveline System - General Information)
Driveline System - General Information (Section Table of Contents)
Driveline System - General Information (SPECIFICATIONS)
Driver Air Bag Module (REMOVAL AND INSTALLATION, Supplemental Restraint System)
Driver Seat Module (DSM) (REMOVAL AND INSTALLATION, Seating)
Driveshaft (DESCRIPTION AND OPERATION)
Driveshaft (DIAGNOSIS AND TESTING)
Driveshaft (Section Table of Contents)
Driveshaft (SPECIFICATIONS)
Driveshaft Runout and Balancing (GENERAL PROCEDURES, Driveline System - General Information)
Driveshaft Slip Yoke Boot (REMOVAL AND INSTALLATION, Driveshaft)
Driveshaft Universal Joint - Single Cardan (DISASSEMBLY AND ASSEMBLY, Driveshaft)
Driveshaft - Exploded View (DISASSEMBLY AND ASSEMBLY, Driveshaft)
Driveshaft - Front (REMOVAL AND INSTALLATION, Driveshaft)
Driveshaft - Rear (REMOVAL AND INSTALLATION, Driveshaft)
Dual Climate Controlled Seat Module (DCSM) (REMOVAL AND INSTALLATION, Seating)
Dust Separator (REMOVAL AND INSTALLATION, Evaporative Emissions)
E
Electronic Engine Controls (DESCRIPTION AND OPERATION)
Electronic Engine Controls (DIAGNOSIS AND TESTING)
Electronic Engine Controls (Section Table of Contents)
Electronic Engine Controls (SPECIFICATIONS)
Electronic Leak Detection (GENERAL PROCEDURES, Climate Control System - General Information and
Diagnostics)
E 3115
Elevation System Check (GENERAL PROCEDURES, Parking Aid)
Engine (ASSEMBLY, Engine - 5.4L (3V))
Engine (DESCRIPTION AND OPERATION, Engine System - General Information)
Engine (DESCRIPTION AND OPERATION, Engine - 5.4L (3V))
Engine (DIAGNOSIS AND TESTING, Engine System - General Information)
Engine (DIAGNOSIS AND TESTING, Engine - 5.4L (3V))
Engine (DISASSEMBLY, Engine - 5.4L (3V))
Engine (INSTALLATION, Engine - 5.4L (3V))
Engine (REMOVAL, Engine - 5.4L (3V))
Engine Cooling (DESCRIPTION AND OPERATION)
Engine Cooling (DIAGNOSIS AND TESTING)
Engine Cooling (Section Table of Conte
Engine Cooling (SPECIFICATIONS)
Engine Emission Control (DESCRIPTION AND OPERATION)
Engine Emission Control (DIAGNOSIS AND TESTING)
Engine Emission Control (Section Table of Contents)
Engine Emission Control (SPECIFICATIONS)
Engine Front Cover (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Engine Ignition (DESCRIPTION AND OPERATION, Engine Ignition - 5.4L (3V))
Engine Ignition (DIAGNOSIS AND TESTING, Engine Ignition - 5.4L (3V))
Engine Ignition Components - Exploded View (REMOVAL AND INSTALLATION, Engine Ignition - 5.4L
(3V))
Engine Ignition - 5.4L (3V) (Section Table of Contents)
Engine Ignition - 5.4L (3V) (SPECIFICATIONS)
Engine Lubrication Components - Exploded View (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Engine Oil Pressure (EOP) Switch (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Engine Support Insulators (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Engine System - General Information (Section Table of Contents)
E 3116
Engine System - General Information (SPECIFICATIONS)
Engine - 5.4L (3V) (Section Table of Contents)
Engine - 5.4L (3V) (SPECIFICATIONS)
Evaporative Emission (EVAP) System Components - Exploded View (REMOVAL AND INSTALLATION,
Evaporative Emissions)
Evaporative Emission Canister (REMOVAL AND INSTALLATION, Evaporative Emissions)
Evaporative Emission Canister Purge Valve (REMOVAL AND INSTALLATION, Evaporative Emissions)
Evaporative Emission Canister Vent Solenoid (REMOVAL AND INSTALLATION, Evaporative Emissions)
Evaporative Emission System Leak Test (GENERAL PROCEDURES, Evaporative Emissions)
Evaporative Emissions (DESCRIPTION AND OPERATION)
Evaporative Emissions (DIAGNOSIS AND TESTING)
Evaporative Emissions (Section Table of Contents)
Evaporative Emissions (SPECIFICATIONS)
Evaporator Core (REMOVAL AND INSTALLATION, Climate Control)
Exhaust Manifold Cleaning and Inspection (GENERAL PROCEDURES, Engine System - General
Information)
Exhaust Manifold - LH (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Exhaust Manifold - RH (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Exhaust System (DESCRIPTION AND OPERATION)
Exhaust System (DIAGNOSIS AND TESTING)
Exhaust System (Section Table of Contents)
Exhaust System (SPECIFICATIONS)
Exhaust System Alignment (GENERAL PROCEDURES, Exhaust System)
Exhaust System - Exploded View (REMOVAL AND INSTALLATION, Exhaust System)
Exhaust Y-Pipe - Dual Catalytic Converter (REMOVAL AND INSTALLATION, Exhaust System)
Exterior Front Door Handle (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry
Systems)
Exterior Lighting (DESCRIPTION AND OPERATION)
Exterior Lighting (Section Table of Contents)
E 3117
Exterior Lighting (SPECIFICATIONS)
Exterior Mirror (REMOVAL AND INSTALLATION, Rear View Mirrors)
Exterior Mirror Control Switch (REMOVAL AND INSTALLATION, Rear View Mirrors)
Exterior Mirror Cover (REMOVAL AND INSTALLATION, Rear View Mirrors)
Exterior Mirror Glass (REMOVAL AND INSTALLATION, Rear View Mirrors)
Exterior Mirror Motor (REMOVAL AND INSTALLATION, Rear View Mirrors)
Exterior Mirror Motor Synchronization - Power Folding (GENERAL PROCEDURES, Rear View Mirrors)
Exterior Mirrors - Exploded View (REMOVAL AND INSTALLATION, Rear View Mirrors)
Exterior Rear Door Handle (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry
Systems)
Exterior Trim (DESCRIPTION AND OPERATION, Exterior Trim and Ornamentation)
Exterior Trim and Ornamentation (Section Table of Contents)
Exterior Trim and Ornamentation (SPECIFICATIONS)
External Controls (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission External

Controls)
External Controls - Column Shift (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmiion External
Controls)
External Controls - Floor Shift (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission External
Controls)
F
Fender (REMOVAL AND INSTALLATION, Front End Body Panels)
Fender Splash Shield (REMOVAL AND INSTALLATION, Front End Body Panels)
Flexplate (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Flexplate Inspection (GENERAL PROCEDURES, Engine System - General Information)
Flexplate or Flywheel and Crankshaft Rear Seal - Exploded View (IN-VEHICLE REPAIR, Engine - 5.4L
(3V))
Floor Duct (REMOVAL AND INSTALLATION, Climate Control)
Fluid Pan, Gasket and Filter (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - 6R80)
F 3118
Fluorescent Dye Leak Detection (GENERAL PROCEDURES, Climate Control System - General Information
and Diagnostics)
Fog Lamp (REMOVAL AND INSTALLATION, Exterior Lighting)
Fog Lamp Bulb (REMOVAL AND INSTALLATION, Exterior Lighting)
Fog Lamps (DIAGNOSIS AND TESTING, Exterior Lighting)
Footwell Duct - Rear (REMOVAL AND INSTALLATION, Climate Control)
Forward Clutch Assembly (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Automatic

Forward/Overdrive Clutch Assembly - Assembly (DISASSEMBLY AND ASSEMBLY OF

SUBASSEMBLIES, Automatic Transaxle/Transmission - 6R80)
Forward/Overdrive Clutch Assembly - Disassembly (DISASSEMBLY AND ASSEMBLY OF

SUBASSEMBLIES, Automatic Transaxle/Transmission - 6R80)
Four Wheel Drive (4WD) Systems (DESCRIPTION AND OPERATION)
Four Wheel Drive (4WD) Systems (Section Table of Contents)
Four Wheel Drive (4WD) Systems (SPECIFICATIONS)
Four Wheel Drive (4WD) Systems - 1-Speed Torque-On-Demand (DIAGNOSIS AND TESTING, Four
Wheel Drive (4WD) Systems)
Four Wheel Drive (4WD) Systems - 2-Speed Torque-On-Demand (DIAGNOSIS AND TESTING, Four
Wheel Drive (4WD) Systems)
Frame and Body Mounting (DESCRIPTION AND OPERATION, Full Frame and Body Mounting)
Frame Members (REMOVAL AND INSTALLATION, Body Repairs)
Front Disc Brake (DESCRIPTION APERATION)
Front Disc Brake (DIAGNOSIS AND TESTING)
Front Disc Brake (Section Table of Contents)
Front Disc Brake (SPECIFICATIONS)
Front Door Latch (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry Systems)
Front Drive Axle (DIAGNOSIS AND TESTING, Front Drive Axle/Differential)
Front Drive Axle and Differential (DESCRIPTION AND OPERATION, Front Drive Axle/Differential)
Front Drive Axle/Differential (Section Table of Contents)
Front Drive Axle/Differential (SPECIFICATIONS)
F 3119
Front Drive Halfshafts (DESCRIPTION AND OPERATION)
Front Drive Halfshafts (DIAGNOSIS AND TESTING)
Front Drive Halfshafts (Section Table of Contents)
Front Drive Halfshafts (SPECIFICATIONS)
Front End Accessory Drive (FEAD) - Exploded View (REMOVAL AND INSTALLATION, Accessory
Drive)
Front End Body Panels (Section Table of Contents)
Front End Body Panels (SPECIFICATIONS)
Front End Body Panels - Exploded View (REMOVAL AND INSTALLATION, Front End Body Panels)
Front Fog Lamp Adjustment (GENERAL PROCEDURES, Exterior Lighting)
Front Impact Severity Sensor (REMOVAL AND INSTALLATION, Supplemental Restraint System)
Front Suspension (DESCRIPTION AND OPERATION, Front Suspension - Four Wheel Drive (4WD))
Front Suspension (DESCRIPTION AND OPERATION, Front Suspension - Rear Wheel Drive (RWD)) Front
Suspension (DIAGNOSIS AND TESTING, Front Suspension - Four Wheel Drive (4WD))
Front Suspension (DIAGNOSIS AND TESTING, Front Suspension - Rear Wheel Drive (RWD))
Front Suspension - Four Wheel Drive (4WD) (Section Table of Contents)
Front Suspension - Four Wheel Drive (4WD) (SPECIFICATIONS)
Front Suspension - Reaive (RWD) (Section Table of Contents)
Front Suspension - Rear Wheel Drive (RWD) (SPECIFICATIONS)
Fuel Charging and Controls (DESCRIPTION AND OPERATION, Fuel Charging and Controls - 5.4L (3V))
Fuel Charging and Controls (DIAGNOSIS AND TESTING, Fuel Charging and Controls - 5.4L (3V))
Fuel Charging and Controls - 5.4L (3V) (Section Table of Contents)
Fuel Charging and Controls - 5.4L (3V) (SPECIFICATIONS)
Fuel Filler Door Cup Bezel (REMOVAL AND INSTALLATION, Exterior Trim and Ornamentation)
Fuel Filter (REMOVAL AND INSTALLATION, Fuel Tank and Lines)
Fuel Injector (REMOVAL AND INSTALLATION, Fuel Charging and Controls - 5.4L (3V))
Fuel Lines (REMOVAL AND INSTALLATION, Fuel Tank and Lines)
Fuel Lines and Fuel Filter - Exploded View (REMOVAL AND INSTALLATION, Fuel Tank and Lines)
F 3120
Fuel Pump Control Module (REMOVAL AND INSTALLATION, Fuel Charging and Controls - 5.4L (3V))
Fuel Pump Module (REMOVAL AND INSTALLATION, Fuel Tank and Lines)
Fuel Rail (REMOVAL AND INSTALLATION, Fuel Charging and Controls - 5.4L (3V))
Fuel Rail and Fuel Injector - Exploded View (REMOVAL AND INSTALLATION, Fuel Charging and
Controls - 5.4L (3V))
Fuel System (DESCRIPTION AND OPERATION, Fuel System - General Information)
Fuel System (DIAGNOSIS AND TESTING, Fuel System - General Information)
Fuel System Pressure Release (GENERAL PROCEDURES, Fuel System - General Information)
Fuel System Pressure Test (GENERAL PROCEDURES, Fuel System - General Information)
Fuel System - General Information (Section Table of Contents)
Fuel System - General Information (SPECIFICATIONS)
Fuel Tank (REMOVAL AND INSTALLATION, Fuel Tank and Lines)
Fuel Tank and Filler Pipe - Exploded View (REMOVAL AND INSTALLATION, Fuel Tank and Lines)
Fuel Tank and Lines (DESCRIPTION AND OPERATION)
Fuel Tank and Lines (DIAGNOSIS AND TESTING)
Fuel Tank and Lines (Section Table of Contents)
Fuel Tank and Lines (SPECIFICATIONS)
Fuel Tank Draining (GENERAL PROCEDURES, Fuel System - General Information)
Fuel Tank Filler Pipe (REMOVAL AND INSTALLATION, Fuel Tank and Lines)
Fuel Tank Pressure Sensor (REMOVAL AND INSTALLATION, Evaporative Emissions)
Full Frame and Body Mounting (Section Table of Contents)
Full Frame and Body Mounting (SPECIFICATIONS)
G
Gear Ratios (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - 6R80)
Generator (REMOVAL AND INSTALLATION, Charging System)
Glass Reseal - Windshield (GENERAL PROCEDURES, Glass, Frames and Mechanisms)
Glass, Frames and Mechanisms (DESCRIPTION AND OPERATION)
G 3121
Glass, Frames and Mechanisms (DIAGNOSIS AND TESTING)
Glass, Frames and Mechanisms (Section Table of Contents)
Glass, Frames and Mechanisms (SPECIFICATIONS)
Glass, Frames and Mechanisms - Exploded View, Front Door (REMOVAL AND INSTALLATION, Glass,
Frames and Mechanisms)
Glass, Frames and Mechanisms - Exploded View, Rear Door (REMOVAL AND INSTALLATION, Glass,
Frames and Mechanisms)
Global Positioning System Module (GPSM) (REMOVAL AND INSTALLATION, Information and
Glove Compartment (REMOVAL AND INSTALLATION, Instrument Panel and Console)
H
Halfshaft (DISASSEMBLY AND ASSEMBLY, Front Drive Halfshafts)
Halfshaft (REMOVAL AND INSTALLATION, Front Drive Halhafts)
Halfshaft (REMOVAL AND INSTALLATION, Rear Drive Halfshafts)
Halfshaft Joint (DISASSEMBLY AND ASSEMBLY, Rear Drive Halfshafts)
Handles, Locks, Latches and Entry Systems (DESCRIPTION AND OPERATION)
Handles, Locks, Latches and Entry Systems (DIAGNOSIS AND TESTING)
Handles, Locks, Latches and Entry Systems (Section Table of Contents)
Handles, Locks, Latches and Entry Systems (SPECIFICATIONS)
Hazard Flasher Lamp Switch (REMOVAL AND INSTALLATION, Exterior Lighting)
Headlamp Adjustment (GENERAL PROCEDURES, Exterior Lighting)
Headlamp Assembly (REMOVAL AND INSTALLATION, Exterior Lighting)
Headlamp Bulb (REMOVAL AND INSTALLATION, Exterior Lighting)
Headlamp Switch (REMOVAL AND INSTALLATION, Exterior Lighting)
Headlamps (DIAGNOSIS AND TESTING, Exterior Lighting)
Headliner (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Heated Oxygen Sensor (HO2S) (REMOVAL AND INSTALLATION, Electronic Engine Controls)
H 3122
Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor - Exploded View (REMOVAL AND
INSTALLATION, Electronic Engine Controls)
Heated Seat Module - Second Row (REMOVAL AND INSTALLATION, Seating)
Heated Seat Switch - Second Row (REMOVAL AND INSTALLATION, Seating)
Heater Core (REMOVAL AND INSTALLATION, Climate Control)
Heater Core And Evaporator Core Housing (REMOVAL AND INSTALLATION, Climate Control)
Heater Hose Coupling (GENERAL PROCEDURES, Climate Control System - General Information and
Diagnostics)
Heating and Ventilation (DESCRIPTION AND OPERATION, Climate Control)
Heating Ventilation Air Conditioning (HVAC) Module (REMOVAL AND INSTALLATION, Climate
Control)
High Voltage Converter/Inverter (Section Table of Contents)
High-Voltage Converter/Inverter (DESCRIPTION AND OPERATION, High Voltage Converter/Inverter)
High-Voltage Converter/Inverter (DIAGNOSIS AND TESTING, High Voltage Converter/Inverter)
Hood Alignment (GENERAL PROCEDURES, Front End Body Panels)
Hood Latch (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry Systems)
Hood Latch Release Handle (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry
Systems)
Horn (DESCRIPTION AND OPERATION)
Horn (DIAGNOSIS AND TESTING)
Horn (REMOVAL AND INSTALLATION)
Horn (Section Table of Contents)
Horn (SPECIFICATIONS)
Hydraulic Brake Actuation (DESCRIPTION AND OPERATION)
Hydraulic Brake Actuation (Section Table of Contents)
Hydraulic Brake Actuation (SPECIFICATIONS)
Hydraulic Circuits (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - 6R80)
Hydraulic Control Unit (HCU) (REMOVAL AND INSTALLATION, Anti-Lock Brake System (ABS) and
Stability Control)
Hydraulic Lash Adjuster (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
H 3123
Hydraulic Lash Adjuster Inspection (GENERAL PROCEDURES, Engine System - General Information)
Hydraulic System (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - 6R80)
I
Identification Codes (DESCRIPTION AND OPERATION)
Identification Codes (Section Table of Contents)
Identification Tags (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - 6R80)
Ignition Coil-On-Plug (REMOVAL AND INSTALLATION, Engine Ignition - 5.4L (3V))
Ignition Lock Cylinder - Functional (REMOVAL AND INSTALLATION, Handles, Locks, Latches and
Entry Systems)
Ignition Lock Cylinder - Non Functional (REMOVAL AND INSTALLATION, Handles, Locks, Latches and
Entry Systems)
Ignition Switch (REMOVAL AND INSTALLATION, Steering Column Switches)
In-Vehicle Temperature Sensor - Expedition (REMOVAL AND INSTALLATION, Climate Control)
In-Vehicle Temperature Sensor - Navigator (REMOVAL AND INSTALLATION, Climate Control)
Inertia Fuel Shutoff (IFS) Switch (REMOVAL AND INSTALLATION, Fuel Tank and Lines)
Information and Entertainment System (DESCRIPTION AND OPERATION, Information and Entertainment
Systems)
Information and Entertainment System (DIAGNOSIS AND TESTING, Information and Entertainment
Systems)
Information and Entertainment SystemsSection Table of Contents)
Information and Entertainment Systems (SPECIFICATIONS)
Information And Message Center (DESCRIPTION AND OPERATION, Instrumentation, Message Center,
and Warning Chimes)
Inner Body Reinforcing Panels (REMOVAL AND INSTALLATION, Body Repairs)
Inner Tie Rod (REMOVAL AND INSTALLATION, Power Steering)
Inspection and Repair After a Supplemental Restraint System (SRS) Deployment (GENERAL
PROCEDURES, Supplemental Restraint System)
Inspection And Verification (DIAGNOSIS AND TESTING, Battery, Mounting and Cables)
Inspection And Verification (DIAGNOSIS AND TESTING, Brake System - General Information)
I 3124
Inspection And Verification (DIAGNOSIS AND TESTING, Charging System)
Inspection And Verification (DIAGNOSIS AND TESTING, Hydraulic Brake Actuation)
Instrument Cluster (IC) (DESCRIPTION AND OPERATION, Instrumentation, Message Center, and Warning
Chimes)
Instrument Cluster (IC) (REMOVAL AND INSTALLATION, Instrumentation, Message Center, and
Warning Chimes)
Instrument Cluster (IC) Lens (REMOVAL AND INSTALLATION, Instrumentation, Message Center, and
Warning Chimes)
Instrument Cluster and Panel Illumination (DESCRIPTION AND OPERATION)
Instrument Cluster and Panel Illumination (DIAGNOSIS AND TESTING)
Instrument Cluster and Panel Illumination (Section Table of Contents)
Instrument Cluster Finish Panel - Expedition (REMOVAL AND INSTALLATION, Instrument Panel and
Console)
Instrument Cluster Finish Panel - Navigator (REMOVAL AND INSTALLATION, Instrument Panel and
Console)
Instrument Panel (REMOVAL AND INSTALLATION, Instrument Panel and Console)
Instrument Panel and Console (Section Table of Contents)
Instrument Panel and Console (SPECIFICATIONS)
Instrument Panel Dimmer Switch (REMOVAL AND INSTALLATION, Instrument Cluster and Panel
Illumination)
Instrument Panel Finish Panel - Center, Expedition (REMOVAL AND INSTALLATION, Instrument Panel
and Console)
Instrument Panel Finish Panel - Center, Navigator (REMOVAL AND INSTALLATION, Instrument Panel
and Console)
Instrument Panel - Exploded View (REMOVAL AND INSTALLATION, Instrument Panel and Console)
Instrumentation, Message Center and Warning Chimes (DIAGNOSIS AND TESTING, Instrumentation,
Message Center, and Warning Chimes)
Instrumentation, Message Center, and Warning Chimes (Section Table of Contents)
Insulation (DESCRIPTION AND OPERATION, Body System - General Information)
Intake Air Distribution and Filtering (DESCRIPTION AND OPERATION)
Intake Air Distribution and Filtering (DIAGNOSIS AND TESTING)
Intake Air Distribution and Filtering (Section Table of Contents)
I 3125
Intake Air Distribution and Filtering (SPECIFICATIONS)
Intake Air System Components - Exploded View (REMOVAL AND INSTALLATION, Intake Air
Distribution and Filtering)
Intake Manifold (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Intake Manifold Assembly (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Engine - 5.4L

(3V))
Integrated Keyhead Transmitter (IKT) Key Programming Using Diagnostic Equipment (GENERAL
PROCEDURES, Anti-Theft - Passive Anti-Theft System (PATS))
Integrated Wheel End (IWE) (REMOVAL AND INSTALLATION, Four Wheel Drive (4WD) Systems)
Interior Door Handle (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry Systems)
Interior Lamp (REMOVAL AND INSTALLATION, Interior Lighting)
Interior Lighting (DESCRIPTION AND OPERATION)
Interior Lighting (DIAGNOSIS AND TESTING)
Interior Lighting (Section Table of Contents)
Interior Rear View Mirror (REMOVAL AND INSTALLATION, Rear View Mirrors)
Interior Trim and Ornamentation (Section Table of Contents)
Interior Trim and Ornamentation (SPECIFICATIONS)
Interior Trim - Exploded View (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Interior/Map Reading Lamp (REMOVAL AND INSTALLATION, Interior Lighting)
Intermediate Clutch Assembly (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Automatic

J
Jacking and Lifting (DESCRIPTAND OPERATION)
Jacking and Lifting (Section Table of Contents)
K
Key Programming Switch State Control (GENERAL PROCEDURES, Anti-Theft - Passive Anti-Theft
System (PATS))
J 3126
Key Programming Using Two Programmed Keys (GENERAL PROCEDURES, Anti-Theft - Passive
Anti-Theft System (PATS))
Keyless Entry Keypad (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry Systems)
Keyless Entry Keypad Code Programming (GENERAL PROCEDURES, Handles, Locks, Latches and Entry
Systems)
Knock Sensor (KS) (REMOVAL AND INSTALLATION, Electronic Engine Controls)
L
Latch Lubrication (GENERAL PROCEDURES, Handles, Locks, Latches and Entry Systems)
Lead Terminal Repair (GENERAL PROCEDURES, Glass, Frames and Mechanisms)
Leakage Inspection (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6R80)
Liftgate (REMOVAL AND INSTALLATION, Body Closures)
Liftgate Alignment (GENERAL PROCEDURES, Body Closures)
Liftgate Latch (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry Systems)
Liftgate Latch Manual Release (GENERAL PROCEDURES, Handles, Locks, Latches and Entry Systems)
Liftgate Latch - Window (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry Systems)
Liftgate Release Switch (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry Systems)
Liftgate Trim Panel (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Liftgate/Trunk Module (LTM) (REMOVAL AND INSTALLATION, Body Closures)
Light Sensor (REMOVAL AND INSTALLATION, Exterior Lighting)
Low/Reverse Clutch Assembly (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Automatic

Lower Arm (REMOVAL AND INSTALLATION, Front Suspension - Four Wheel Drive (4WD))
Lower Arm (REMOVAL AND INSTALLATION, Front Suspension - Rear Wheel Drive (RWD))
Lower Arm (REMOVAL AND INSTALLATION, Rear Suspension)
Lumbar Assembly (REMOVAL AND INSTALLATION, Seating)
K 3127
M
Maintenance Schedule (Section Table of Contents)
Maintenance Schedules - Gasoline Engines (DESCRIPTION AND OPERATION, Maintenance Schedule)
Major Components (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - 6R80)
Manual Control Lever Shaft and Seal (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - 6R80)
Mass Air Flow (MAF) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls)
Mechanical Components and Functions (DESCRIPTION AND OPERATION, Automatic

Mechatronic Assembly (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Automatic

Mechatronic Assembly (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - 6R80)
Memory Position Programming (GENERAL PROCEDURES, Seating)
Memory Set Switch (REMOVAL AND INSTALLATION, Seating)
Message Center Configuration (GENERAL PROCEDURES, Instrumentation, Message Center, and Warning
Chimes)
Message Center Switch (REMOVAL AND INSTALLATION, Instrumentation, Message Center, and
Warning Chimes)
Mode Door Actuator - Air Inlet Door (REMOVAL AND INSTALLATION, Climate Control)
Mode Door Actuator - Defrost/Panel/Floor Door (REMOVAL AND INSTALLATION, Climate Control)
Module Communications Network (Section Table of Contents)
Module Configuration (DIAGNOSIS AND TESTING)
Module Configuration (Section Table of Contents)
Module Controlled Functions (DESCRIPTION AND OPERATION, Multifunction Electronic Modules)
Muffler and Tailpipe (REMOVAL AND INSTALLATION, Exhaust System)
Multifunction Electronic Modules (Section Table of Contents)
Multifunction Electronic Modules (SPECIFICATIONS)
MyKey Programming (GENERAL PROCEDURES, Anti-Theft - Passive Anti-Theft System (PATS))
MyKey Restrictions on Vehicle Operation (DIAGNOSIS AND TESTING, Anti-Theft - Passive Anti-Theft
System (PATS))
M 3128
N
Noise, Vibration and Harshness (Section Table of Contents)
Noise, Vibration and Harshness (NVH) (DIAGNOSIS AND TESTING, Noise, Vibration and Harshness)
O
Oil Filter Adapter (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Oil Level Indicator and Tube (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Oil Pan (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Oil Pump (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Oil Pump Screen and Pickup Tube (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Output Shaft Seal (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - 6R80)
Output State Control (OSC) Mode (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission -
6R80)
Overdrive Clutch Assembly (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Automatic

P
Parking Aid (DESCRIPTION AND OPERATION)
Parking Aid (DIAGNOSIS AND TESTING)
Parking Aid (Section Table of Contents)
Parking Aid (SPECIFICATIONS)
Parking Aid Module (PAM) (REMOVAL AND INSTALLATION, Parking Aid)
Parking Aid Sensor - Front (REMOVAL AND INSTALLATION, Parking Aid)
Parking Aid Sensor - Rear (REMOVAL AND INSTALLATION, Parking Aid)
Parking Aid Speaker (REMOVAL AND INSTALLATION, Parking Aid)
Parking Aid - Video (DIAGNOSIS AND TESTING, Parking Aid)
Parking Brake (DESCRIPTION AND OPERATION, Parking Brake and Actuation)
Parking Brake (DIAGNOSIS AND TESTING, Parking Brake and Actuation)
N 3129
Parking Brake and Actuation (Section Table of Contents)
Parking Brake and Actuation (SPECIFICATIONS)
Parking Brake Cable Tension Release (GENERAL PROCEDURES, Parking Brake and Actuation)
Parking Brake Cable - Front (REMOVAL AND INSTALLATION, Parking Brake and Actuation)
Parking Brake Cable - Rear, LH (REMOVAL AND INSTALLATION, Parking Brake and Actuation)
Parking Brake Cable - Rear, RH (REMOVAL AND INSTALLATION, Parking Brake and Actuation)
Parking Brake Control (REMOVAL AND INSTALLATION, Parking Brake and Actuation)
Parking Brake Shoe Adjustment (GENERAL PROCEDURES, Parking Brake and Actuation)
Parking Brake Shoes (REMOVAL AND INSTALLATION, Parking Brake and Actuation)
Parking Lamp - Liftgate (REMOVAL AND INSTALLATION, Exterior Lighting)
Parking, Rear and License Plate Lamps (DIAGNOSIS AND TESTING, Exterior Lighting)
Passenger Air Bag Module (REMOVAL AND INSTALLATION, Supplemental Restraint System)
Passive Anti-Theft System (PATS) Parameter Reset (GENERAL PROCEDURES, Anti-Theft - Passive
Passive Anti-Theft System (PATS) Transceiver (REMOVAL AND INSTALLATION, Anti-Theft - Passive
Anti-Theft SysATS))
Pinch Strip Switch (REMOVAL AND INSTALLATION, Body Closures)
Pinpoint Test (DIAGNOSIS AND TESTING, Battery, Mounting and Cables)
Pinpoint Test (DIAGNOSIS AND TESTING, Charging System)
Pinpoint Tests (DIAGNOSIS AND TESTING, Brake System - General Information)
Pinpoint Tests (DIAGNOSIS AND TESTING, Hydraulic Brake Actuatn)
Pinpoint Tests - OSC Equipped Vehicle (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission -
6R80)
Piston (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Engine - 5.4L (3V))
Piston Diameter (GENERAL PROCEDURES, Engine System - General Information)
Piston Inspection (GENERAL PROCEDURES, Engine System - General Information)
Piston Pin Diameter (GENERAL PROCEDURES, Engine System - General Information)
Piston Ring End Gap (GENERAL PROCEDURES, Engine System - General Information)
Piston Ring-to-Groove Clearance (GENERAL PROCEDURES, Engine System - General Information)
P 3130
Piston Selection (GENERAL PROCEDURES, Engine System - General Information)
Piston To Cylinder Bore Clearance (GENERAL PROCEDURES, Engine System - General Information)
Plastic Components (DESCRIPTION AND OPERATION, Body Repairs)
Plastics Identification (GENERAL PROCEDURES, Body Repairs)
Plastics Refinishing (GENERAL PROCEDURES, Body Repairs)
Plastics Repair (GENERAL PROCEDURES, Body Repairs)
Plenum Chamber (REMOVAL AND INSTALLATION, Climate Control)
Positive Crankcase Ventilation (PCV) System Components (REMOVAL AND INSTALLATION, Engine
Emission Control)
Power Brake Actuation (Section Table of Contents)
Power Brake Actuation (SPECIFICATIONS)
Power Brake System (DIAGNOSIS AND TESTING, Power Brake Actuation)
Power Liftgate (DIAGNOSIS AND TESTING, Body Closures)
Power Liftgate Initialization (GENERAL PROCEDURES, Body Closures)
Power Liftgate Motor (REMOVAL AND INSTALLATION, Body Closures)
Power Liftgate Rod (REMOVAL AND INSTALLATION, Body Closures)
Power Point (REMOVAL AND INSTALLATION, Instrument Panel and Console)
Power Point (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Power Running Board (PRB) (DIAGNOSIS AND TESTING, Exterior Trim and Ornamentation)
Power Running Board (PRB) (REMOVAL AND INSTALLATION, Exterior Trim and Ornamentation)
Power Running Board (PRB) Bracket (REMOVAL AND INSTALLATION, Exterior Trim and
Ornamentation)
Power Running Board (PRB) Module (REMOVAL AND INSTALLATION, Exterior Trim and
Ornamentation)
Power Running Board (PRB) Motor (REMOVAL AND INSTALLATION, Exterior Trim and Ornamentation)
Power Running Board (PRB) Step (REMOVAL AND INSTALLATION, Exterior Trim and Ornamentation)
Power Steering (DESCRIPTION AND OPERATION)
Power Steering (DIAGNOSIS AND TESTING)
Power Steering (Section Table of Contents)
P 3131
Power Steering (SPECIFICATIONS)
Power Steering Fluid Cooler (REMOVAL AND INSTALLATION, Power Steering)
Power Steering Fluid Reservoir (REMOVAL AND INSTALLATION, Power Steering)
Power Steering Pump (REMOVAL AND INSTALLATION, Power Steering)
Power Steering Pump to Steering Gear Pressure Line (REMOVAL AND INSTALLATION, Power Steering)
Power Steering System Filling (GENERAL PROCEDURES, Steering System)
Power Steering System Flushing (GENERAL PROCEDURES, Steering System)
Power Steering System Purging (GENERAL PROCEDURES, Steering System)
Power-Fold Seat Motor (REMOVAL AND INSTALLATION, Seating)
Powertrain Control Module (PCM) (REMOVAL AND INSTALLATION, Electronic Engine Controls)
Powertrain/Drivetrain Mount Neutralizing (GENERAL PROCEDURES, Engine System - General

Information)
Preliminary Inspection (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6R80)
Principles of Operation (DIAGNOSIS AND TESTING, Battery, Mounting and Cables)
Principles of Operation (DIAGNOSIS AND TESTING, Brake System - General Information)
Principles of Operation (DIAGNOSIS AND TESTING, Charging System)
Principles of Operation (DIAGNOSIS AND TESTING, Hydraulic Brake Actuation)
Programmable Module Installation (PMI) (GENERAL PROCEDURES, Module Configuration)
Puddle Lamp (REMOVAL AND INSTALLATION, Exterior Lighting)
Pump Assembly (DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES, Automatic

Pyrotechnic Device Disposal (GENERAL PROCEDURES, Supplemental Restraint System)
bsp;
Q
Quarter Trim Panel (REMOVAL AND INSTALLATION, Interior Trim and Ornamentation)
Quick Connect Coupling (GENERAL PROCEDURES, Fuel System - General Information)
Q 3132
R
Radiator (REMOVAL AND INSTALLATION, Engine Cooling)
Radiator Grille (REMOVAL AND INSTALLATION, Exterior Trim and Ornamentation)
Radiator Grille Support (REMOVAL AND INSTALLATION, Front End Body Panels)
Rain Sensor (REMOVAL AND INSTALLATION, Wipers and Washers)
Rain Sensor Bracket (REMOVAL AND INSTALLATION, Wipers and Washers)
Range Selection (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - 6R80)
Rear Axle Housing Support Insulator (REMOVAL AND INSTALLATION, Rear Drive Axle/Differential -
Ford 9.75-Inch Ring Gear)
Rear Disc Brake (DESCRIPTION AND OPERATION)
Rear Disc Brake (DIAGNOSIS AND TESTING)
Rear Disc Brake (Section Table of Contents)
Rear Disc Brake (SPECIFICATIONS)
Rear Door Latch (REMOVAL AND INSTALLATION, Handles, Locks, Latches and Entry Systems)
Rear Drive Axle and Differential (DESCRIPTION AND OPERATION, Rear Drive Axle/Differential - Ford
Rear Drive Axle and Differential (DIAGNOSIS AND TESTING, Rear Drive Axle/Differential - Ford
Rear Drive Axle/Differential - Ford 9.75-Inch Ring Gear (Section Table of Contents)
Rear Drive Axle/Differential - Ford 9.75-Inch Ring Gear (SPECIFICATIONS)
Rear Drive Halfshafts (DESCRIPTION AND OPERATION)
Rear Drive Halfshafts (DIAGNOSIS AND TESTING)
Rear Drive Halfshafts (Section Table of Contents)
Rear Drive Halfshafts (SPECIFICATIONS)
Rear Suspension (DESCRIPTION AND OPERATION)
Rear Suspension (DIAGNOSIS AND TESTING)
Rear Suspension (Section Table of Contents)
Rear Suspension (SPECIFICATIONS)
Rear View Mirrors (DESCRIPTION AND OPERATION)
R 3133
Rear View Mirrors (Section Table of Contents)
Rear View Mirrors (SPECIFICATIONS)
Rear View Mirrors - Exterior (DIAGNOSIS AND TESTIN Rear View Mirrors)
Rear View Mirrors - Interior (DIAGNOSIS AND TESTING, Rear View Mirrors)
Receiver Drier Cartridge (REMOVAL AND INSTALLATION, Climate Control)
Refinishing - Environmental Damage (GENERAL PROCEDURES, Body Repairs)
Refinishing - Manufacturing Damage (GENERAL PROCEDURES, Body Repairs)
Refrigerant IdentificTesting (GENERAL PROCEDURES, Climate Control System - General Information and
Diagnostics)
Refrigerant Oil Adding (GENERAL PROCEDURES, Climate Control System - General Information and
Diagnostics)
Refrigerant System Filtering Following Air Conditioning (A/C) Compressor Installation (GENERAL
PROCEDURES, Climate Control System - General Information and Diagnostics)
Register (REMOVAL AND INSTALLATION, Auxiliary Climate Control)
Register - Center, Navigator (REMOVAL AND INSTALLATION, Climate Control)
Register - Driver Side, Navigator (REMOVAL AND INSTALLATION, Climate Control)
Register - Expedition (REMOVAL AND INSTALLATION, Climate Control)
Register - Passenger Side, Navigator (REMOVAL AND INSTALLATION, Climate Control)
Remote Convenience (Section Table of Contents)
Remote Convenience (SPECIFICATIONS)
Remote Keyless Entry (RKE) Transmitter Programming (GENERAL PROCEDURES, Handles, Locks,
Latches and Entry Systems)
Remote Memory Activation (GENERAL PROCEDURES, Handles, Locks, Latches and Entry Systems)
Remote Memory Deactivation (GENERAL PROCEDURES, Handles, Locks, Latches and Entry Systems)
Restoring Corrosion Protection Following Repair (GENERAL PROCEDURES, Body Repairs)
Restraints Control Module (RCM) (REMOVAL AND INSTALLATION, Supplemental Restraint System)
Reversing Lamps (DIAGNOSIS AND TESTING, Exterior Lighting)
Ride Height Adjustments (GENERAL PROCEDURES, Vehicle Dynamic Suspension)
Ride Height Measurement (GENERAL PROCEDURES, Suspension System - General Information)
R 3134
Ring Gear Backlash Adjustment (GENERAL PROCEDURES, Rear Drive Axle/Differential - Ford 9.75-Inch
Ring Gear)
Rivet Nut Replacement (GENERAL PROCEDURES,plemental Restraint System)
Roller Follower Inspection (GENERAL PROCEDURES, Engine System - General Information)
Roof Opening Panel (DESCRIPTION AND OPERATION)
Roof Opening Panel (DIAGNOSIS AND TESTING)
Roof Opening Panel (Section Table of Contents)
Roof Opening Panel (SPECIFICATIONS)
Roof Opening Panel Alignment (GENERAL PROCEDURES, Roof Opening Panel)
Roof Opening Panel Frame (REMOVAL AND INSTALLATION, Roof Opening Panel)
Roof Opening Panel Glass (REMOVAL AND INSTALLATION, Roof Opening Panel)
Roof Opening Panel Motor (REMOVAL AND INSTALLATION, Roof Opening Panel)
Roof Opening Panel Motor Initialization (GENERAL PROCEDURES, Roof Opening Panel)
Roof Opening Panel Rear Trough Guide (REMOVAL AND INSTALLATION, Roof Opening Panel)
Roof Opening Panel Shield (REMOVAL AND INSTALLATION, Roof Opening Panel)
Roof Opening Panel Weatherstrip (REMOVAL AND INSTALLATION, Roof Opening Panel)
Roof Opening Panel - Exploded View (REMOVAL AND INSTALLATION, Roof Opening Panel)
Roof nel (REMOVAL AND INSTALLATION, Body Repairs)
S
Safety Belt Buckle and Pretensioner (REMOVAL AND INSTALLATION, Safety Belt System)
Safety Belt Buckle - Second Row, 20 Percent Seat (REMOVAL AND INSTALLATION, Safety Belt System)
Safety Belt Buckle - Second Row, 40 Percent Seat (REMOVAL AND INSTALLATION, Safety Belt System)
Safety Belt Buckle - Third Row, 40 Percent Seat (REMOVAL AND INSTALLATION, Safety Belt System)
Safety Belt Buckle - Third Row, 60 Percent Seat (REMOVAL AND INSTALLATION, Safety Belt System)
Safety Belt Cleaning (GENERAL PROCEDURES, Safety Belt System)
Safety Belt Maintenance (GENERAL PROCEDURES, Safety Belt System)
Safety Belt Procedure After a Collision (GENERAL PROCEDURES, Safety Belt System)
S 3135
Safety Belt Retractor - Front (REMOVAL AND INSTALLATION, Safety Belt System)
Safety Belt Retractor - Second Row and Third Row, Outboard (REMOVAL AND INSTALLATION, Safety
Belt System)
Safety Belt Retractor - Second Row, Center (REMOVAL AND INSTALLATION, Safety Belt System)
Safety Belt Retractor - Third Row, Center (REMOVAL AND INSTALLATION, Safety Belt System)
Safety Belt Shoulder Height Adjuster (REMOVAL AND INSTALLATION, Safety Belt System)
Safety Belt System (DESCRIPTION AND OPERATION)
Safety Belt System (DIAGNOSIS AND TESTING)
Safety Belt System (Section Table of Contents)
Safety Belt System (SPECIFICATIONS)
Safety Belt Tongue Rotated on Belt (GENERAL PROCEDURES, Safety Belt System)
Safety Belt Twisted at the Safety Belt Guide - Outboard (GENERAL PROCEDURES, Safety Belt System)
Safety Canopy Module (REMOVAL AND INSTALLATION, Supplemental Restraint System)
Safety Warnings (DESCRIPTION AND OPERATION, Service Information)
Satellite Digital Audio Receiver System (SDARS) Module (REMOVAL AND INSTALLATION,
Information and Entertainment Systems)
Sealers (DESCRIPTION AND OPERATION, Body Repairs)
Seat Armrest - Second Row (REMOVAL AND INSTALLATION, Seating)
Seat Backrest Cover - Front (REMOVAL AND INSTALLATION, Seating)
Seat Backrest Cover - Second Row, 20 Percent (REMOVAL AND INSTALLATION, Seating)
Seat Backrest Cover - Second Row, 40 Percent (REMOVAL AND INSTALLATION, Seating)
Seat Backrest Cover - Third Row (REMOVAL AND INSTALLATION, Seating)
Seat Backrest Heater Mat (REMOVAL AND INSTALLATION, Seating)p>
Seat Backrest Thermo-Electric Device (REMOVAL AND INSTALLATION, Seating)
Seat Backrest - Front (DISASSEMBLY AND ASSEMBLY, Seating)
Seat Backrest - Front (REMOVAL AND INSTALLATION, Seating)
Seat Backrest - Second Row, 20 Percent (DISASSEMBLY AND ASSEMBLY, Seating)
Seat Backrest - Second Row, 20 Percent (REMOVAL AND INSTALLATIOng)
S 3136
Seat Backrest - Third Row, 40 Percent (DISASSEMBLY AND ASSEMBLY, Seating)
Seat Backrest - Third Row, 40 Percent (REMOVAL AND INSTALLATION, Seating)
Seat Backrest - Third Row, 60 Percent (DISASSEMBLY AND ASSEMBLY, Seating)
Seat Backrest - Third Row, 60 Percent (REMOVAL AND INSTALLATION, Seating)
Seat Control Switch t (REMOVAL AND INSTALLATION, Seating)
Seat Control Switch - Third Row (REMOVAL AND INSTALLATION, Seating)
Seat Cushion Cover - Front (REMOVAL AND INSTALLATION, Seating)
Seat Cushion Cover - Second Row, 20 Percent (REMOVAL AND INSTALLATION, Seating)
Seat Cushion Cover - Second Row, 40 Percent (REMOVAL AND INSTALLATION, Seating)
Seat Cushion Heater Mat (REMOVAL AND INSTALLATION, Seating)
Seat Cushion Thermo-Electric Device (REMOVAL AND INSTALLATION, Seating)
Seat Cushion - Front (DISASSEMBLY AND ASSEMBLY, Seating)
Seat Cushion - Second Row, 20 Percent (DISASSEMBLY AND ASSEMBLY, Seating)
Seat Cushion - Third Row, 40 Percent (DISASSEMBLY AND ASSEMBLY, Seating)
Seat Cushion - Third Row, 60 Percent (DISASSEMBLY AND ASSEMBLY, Seating)
Seat Position Sensor (REMOVAL AND INSTALLATION, Supplemental Restraint System)
Seat Track - Manual (REMOVAL AND INSTALLATION, Seating)
Seat Track - Power (REMOVAL AND INSTALLATION, Seating)
Seat - Exploded View, Front (REMOVAL AND INSTALLATION, Seating)
Seat - Exploded View, Second Row (REMOVAL AND INSTALLATION, Seating)
Seat - Exploded View, Third Row (REMOVAL AND INSTALLATION, Seating)
Seat - Front (REMOVAL AND INSTALLATION, Seating)
Seat - Second Row, 20 Percent (REMOVAL AND INSTALLATION, Seating)
Seat - Third Row (REMOVAL AND INSTALLATION, Seating)
Seating (Section Table of Contents)
Seating (SPECIFICATIONS)
Seats (DESCRIPTION AND OPERATION, Seating)
S 3137
Seats (DIAGNOSIS AND TESTING, Seating)
Sectioning Guidelines (GENERAL PROCEDURES, Body Repairs)
Selector Lever Bezel (REMOVAL AND INSTALLATION, Automatic Transaxle/Transmission External

Controls)
Selector Lever Cable Adjustment (GENERAL PROCEDURES, Automatic Transaxle/Transmission External

Controls)
Selector Lever Cable and Bracket - Column Shift (REMOVAL AND INSTALLATION, Automatic
Selector Lever Indicator Bulb (REMOVAL AND INSTALLATION, Instrument Cluster and Panel
Illumination)
Selector Lever Knob (REMOVAL AND INSTALLATION, Automatic Transaxle/Transmission External

Controls)
Selector Lever Mechanism (REMOVAL AND INSTALLATION, Automatic Transaxle/Transmission

External Controls)
Selector Lever - Column Shift (REMOVAL AND INSTALLATION, Automatic Transaxle/Transmission

External Controls)
Selector Lever - Floor Shift (REMOVAL AND INSTALLATION, Automatic Transaxle/Transmission

External Controls)
Service Information (Section Table of Contents)
Shift Patterns (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - 6R80)
Shift Point Road Test (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6R80)
Shock Absorber and Spring Assembly (REMOVAL AND INSTALLATION, Front Suspension - Four Wheel
Drive (4WD))
Shock Absorber and Spring Assembly (REMOVAL AND INSTALLATION, Front Suspension - Rear Wheel
Drive (RWD))
Shock Absorber and Spring Assembly (REMOVAL AND INSTALLATION, Rear Suspension)
Side Air Bag Module (REMOVAL AND INSTALLATION, Supplemental Restraint System)
Side Impact Sensor - C-Pillar (REMOVAL AND INSTALLATION, Supplemental Restraint System)
Side Turn Signal Lamp - Signal Mirror (REMOVAL AND INSTALLATION, Exterior Lighting)
Smart Junction Box (SJB) (DIAGNOSIS AND TESTING, Multifunction Electronic Modules)
Smart Junction Box (SJB) (REMOVAL AND INSTALLATION, Multifunction Electronic Modules)
Sound Deadeners and Insulators (DESCRIPTION AND OPERATION, Body Repairs)
S 3138
Spare Key Programming - Unlimited Key Mode (GENERAL PROCEDURES, Anti-Theft - Passive
Spare Key Programming - Using Diagnostic Equipment (GENERAL PROCEDURES, Anti-Theft - Passive
Spark Plug Inspection (GENERAL PROCEDURES, Engine System - General Information)
Spark Plugs (REMOVAL AND INSTALLATION, Engine Ignition - 5.4L (3V))
Speaker - Door (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Speaker - Instrument Panel (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Speaker - Subwoofer (REMOVAL AND INSTALLATION, Information and Entertainment Systems)
Special Testing Procedures (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6R80)
Spring Lock Coupling (GENERAL PROCEDURES, Climate Control System - General Information and
Diagnostics)
Sprockets (GENERAL PROCEDURES, Engine System - General Information) Stability/Traction Control

Switch - Expedition (REMOVAL AND INSTALLATION, Anti-Lock Brake System (ABS) and Stability
Control)
Stability/Traction Control Switch - Navigator (REMOVAL AND INSTALLATION, Anti-Lock Brake System
(ABS) and Stability Control)
Stabilizer Bar and Link (REMOVAL AND INSTALLATION, Front Suspension - Four Wheel Drive (4WD))
Stabilizer Bar and Link (REMOVAL AND INSTALLATION, Front Suspension - Rear Wheel Drive (RWD))
Stabilizer Bar and Link (REMOVAL AND INSTALLATION, Rear Suspension)
Starter Motor (REMOVAL AND INSTALLATION, Starting System)
Starting System (DESCRIPTION AND OPERATION)
Starting System (DIAGNOSIS AND TESTING)
Starting System (Section Table of Contents)
Starting System (SPECIFICATIONS)
Steering Column (DESCRIPTION AND OPERATION)
Steering Column (DIAGNOSIS AND TESTING)
Steering Column (DISASSEMBLY AND ASSEMBLY)
Steering Column (REMOVAL AND INSTALLATION)
Steering Column (Section Table of Contents)
S 3139
Steering Column (SPECIFICATIONS)
Steering Column Motor (REMOVAL AND INSTALLATION, Steering Column)
Steering Column Multifunction Switch (REMOVAL AND INSTALLATION, Steering Column Switches)
Steering Column Shaft (REMOVAL AND INSTALLATION, Steering Column)
Steering Column Shroud (REMOVAL AND INSTALLATION, Steering Column)
Steering Column Switches (DESCRIPTION AND OPERATION)
Steering Column Switches (DIAGNOSIS AND TESTING)
Steering Column Switches (Section Table of Contents)
Steering Column Switches (SPECIFICATIONS)
Steering Gear (REMOVAL AND INSTALLATION, Power Steering)
Steering Gear to Fluid Cooler Return Hose (REMOVAL AND INSTALLATION, Power Steering)
Steering Gear Turn Tubes (REMOVAL AND INSTALLATION, Power Steering)
Steering System (DESCRIPTION AND OPERATION)
Steering System (DIAGNOSIS AND TESTING)
Steering System (Section Table of Contents)
Steering System (SPECIFICATIONS)
Steering Wheel (REMOVAL AND INSTALLATION, Steering Column)
Steering Wheel Controls - Expedition (REMOVAL AND INSTALLATION, Information and Entertainment
Systems)
Steering Wheel Controls - Navigator (REMOVAL AND INSTALLATION, Information and Entertainment
Systems)
Steering Wheel Rotation Sensor (REMOVAL AND INSTALLATION, Anti-Lock Brake System (ABS) and
Stability Control)
Steering Wheel Wrap Bonding (GENERAL PROCEDURES, Steering Column)
Stepped Unlock Programming (GENERAL PROCEDURES, Handles, Locks, Latches and Entry Systems)
Stoplamp Switch (REMOVAL AND INSTALLATION, Exterior Lighting)
Stoplamps (DIAGNOSIS AND TESTING, Exterior Lighting)
Striker and Wiper Pivot Shaft Assembly - Rear (REMOVAL AND INSTALLATION, Wipers and Washers)
Stub Shaft Pilot Bearing and Seal (IN-VEHICLE REPAIR, Front Drive Axle/Differential)
S 3140
Stub Shaft Pilot Bearing and Seal (IN-VEHICLE REPAIR, Rear Drive Axle/Differential - Ford 9.75-Inch
Ring Gear)
Supplemental Restraint System (Section Table of Contents)
Supplemental Restraint System (SPECIFICATIONS)
Supplemental Restraint System (SRS) Deactivation and Reactivatn (GENERAL PROCEDURES,

Supplemental Restraint System (SRS) Depowering and Repowering (GENERAL PROCEDURES,

Suspension Height Sensor (REMOVAL AND INSTALLATION, Vehicle Dynamic Suspension)
Suspension System (DIAGNOSIS AND TESTING, Suspension System - General Information)
Suspension System - General Information (Section Table of Contents)
Suspension System - General Information (SPECIFICATIONS)
Symbols Glossary (DESCRIPTION AND OPERATION, Service Information)
Symptom Chart (DIAGNOSIS AND TESTING, Brake System - General Information)
Symptom Chart (DIAGNOSIS AND TESTING, Charging System)
Symptom Charts (DIAGNOSIS AND TESTING, Hydraulic Brake Actuation)
T
Temperature Blend Door Actuator - LH (REMOVAL AND INSTALLATION, Climate Control)
Temperature Blend Door Actuator - RH (REMOVAL AND INSTALLATION, Climate Control)
Thermostat and Thermostat Housing (REMOVAL AND INSTALLATION, Engine Cooling)
Thermostatic Expansion Valve (REMOVAL AND INSTALLATION, Climate Control)
Thermostatic Expansion Valve Manifold and Tube Assembly (REMOVAL AND INSTALLATION, Climate
Control)
Thermostatic Expansion Valve - Expedition EL, Navigator L (REMOVAL AND INSTALLATION, Auxiliary
Climate Control)
Thermostatic Expansion Valve - Expedition, Navigator (REMOVAL AND INSTALLATION, Auxiliary

Climate Control)
Throttle Body (REMOVAL AND INSTALLATION, Fuel Charging and Controls - 5.4L (3V))
Throttle Position (TP) Sensor (REMOVAL AND INSTALLATION, Electronic Engine Controls)
T 3141
Timing Drive Components (IN-VEHICLE REPAIR, Engine - 5.4L (3V)) Tire Pressure Monitoring System
(TPMS) (DIAGNOSIS AND TESTING, Wheels and Tires)
Tire Pressure Monitoring System (TPMS) Sensor (DISASSEMBLY AND ASSEMBLY OF

SUBASSEMBLIES, Wheels and Tires)
Tire Pressure Monitoring System (TPMS) Sensor Activation (GENERAL PROCEDURES, Wheels and Tires)
Tire Pressure Monitoring System (TPMS) Sensor Training (GENERAL PROCEDURES, Wheels and Tires)
Toe Adjustment - Front (GENERAL PROCEDURES, Suspension System - General Information)
Toe Adjustment - Rear (GENERAL PROCEDURES, Suspension System - General Information)
Toe Link (REMOVAL AND INSTALLATION, Rear Suspension)
Torque Converter (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - 6R80)
Torque Converter Contamination Inspection (GENERAL PROCEDURES, Automatic

Torque Converter Diagnosis (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6R80)
Trailer Hitch (REMOVAL AND INSTALLATION, Full Frame and Body Mounting)
Trailer Lamps (DIAGNOSIS AND TESTING, Exterior Lighting)
Trailing Arm - Lower (REMOVAL AND INSTALLATION, Rear Suspension)
Trailing Arm - Upper (REMOVAL AND INSTALLATION, Rear Suspension)
Transaxle/Transmission Cooling (Section Table of Contents)
Transaxle/Transmission Cooling (SPECIFICATIONS)
Transfer Case (DESCRIPTION AND OPERATION)
Transfer Case (DIAGNOSIS AND TESTING)
Transfer Case (INSTALLATION)
Transfer Case (REMOVAL)
Transfer Case (Section Table of Contents)
Transfer Case (SPECIFICATIONS)
Transfer Case Draining and Filling (GENERAL PROCEDURES, Transfer Case)
Transfer Case Rear Output Shaft Seal (IN-VEHICLE REPAIR, Transfer Case)
Transfer Case Shift Motor (REMOVAL AND INSTALLATION, Four Wheel Drive (4WD) Systems)
Transfer Case - Expedition (DISASSEMBLY AND ASSEMBLY, Transfer Case)
T 3142
Transfer Case - Navigator (DISASSEMBLY AND ASSEMBLY, Transfer Case)
Transmission (ASSEMBLY, Automatic Transaxle/Transmission - 6R80)
Transmission (DISASSEMBLY, Automatic Transaxle/Transmission - 6R80)
Transmissiotor Layouts (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6R80)
Transmission Control (TC) Switch - Column Shift (REMOVAL AND INSTALLATION, Automatic
Transmission Control (TC) Switch - Floor Shift (REMOVAL AND INSTALLATION, Automatic
Transmission Cooling (DESCRIPTION AND OPERATION, Transaxle/Transmission Cooling)
Transmission Cooling (DIAGNOSIS AND TESTING, Transaxle/Transmission Cooling)
Transmission Description (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - 6R80)
Transmission Drive Cycle Test (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6R80)
Transmission Electronic Control System (DESCRIPTION AND OPERATION, Automatic

Transmission Fluid Cooler (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6R80)
Transmission Fluid Cooler Backflushing and Cleaning (GENERAL PROCEDURES, Automatic

Transaxle/Transmission - 6R80) p class="nospace">Transmission Fluid Cooler Hoses (REMOVAL AND
INSTALLATION, Transaxle/Transmission Cooling)
Transmission Fluid Cooler Tubes (REMOVAL AND INSTALLATION, Transaxle/Transmission Cooling)
Transmission Fluid Drain and Refill (GENERAL PROCEDURES, Automatic Transaxle/Transmission -

6R80)
Transmission Fluid Exchange (GENERAL PROCEDURES, Automatic Transaxle/Transmission - 6R80)
Transmission Fluid Level Check (GENERAL PROCEDURES, Automatic Transaxle/Transmission - 6R80)
Transmission Insulator and Retainer (IN-VEHICLE REPAIR, Automatic Transaxle/Transmission - 6R80)
Transmission Operation (DESCRIPTION AND OPERATION, Automatic Transaxle/Transmission - 6R80)
Transmission Support Crossmember (REMOVAL AND INSTALLATION, Full Frame and Body Mounting)
Transmission - Four Wheel Drive (4WD) (INSTALLATION, Automatic Transaxle/Transmission - 6R80)
Transmission - Four Wheel Drive (4WD) (REMOVAL, Automatic Transaxle/Transmission - 6R80)
Transmission - Rear Wheel Drive (RWD) (INSTALLATION, Automatic Transaxle/Transmission - 6R80)
Transmission - Rear Wheel Drive (RWD) (REMOVAL, Automatic Transaxle/Transmission - 6R80)
T 3143
Turn Signal and Hazard Lamps (DIAGNOSIS AND TESTING, Exterior Lighting)
U
Universal Joints (DESCRIPTION AND OPERATION, Driveshaft)
Universal Serial Bus (USB) Cable and Port (REMOVAL AND INSTALLATION, Information and
Universal Transmitter (DESCRIPTION AND OPERATION, Remote Convenience)
Universal Transmitter (DIAGNOSIS AND TESTING, Remote Convenience)
Universal Transmitter Programming (GENERAL PROCEDURES, Remote Convenience)
Upper Arm (REMOVAL AND INSTALLATION, Front Suspension - Four Wheel Drive (4WD))
Upper Arm (REMOVAL AND INSTALLATION, Front Suspension - Rear Wheel Drive (RWD))
Upper Arm (REMOVAL AND INSTALLATION, Rear Suspension)
Using This Manual (DESCRIPTION AND OPERATION, Service Information)
V
Valve Cover - LH (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Valve Cover - RH (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Valve Guide Inner Diameter (GENERAL PROCEDURES, Engine System - General Information)
Valve Inspection (GENERAL PROCEDURES, Engine System - General Information)
Valve Seals (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Valve Seat Inspection (GENERAL PROCEDURES, Engine System - General Information)
Valve Seat Runout (GENERAL PROCEDURES, Engine System - General Information)
Valve Seat Width (GENERAL PROCEDURES, Engine System - General Information)
Valve Spring Free Length (GENERAL PROCEDURES, Engine System - General Information)
Valve Spring Installed Length (GENERAL PROCEDURES, Engine System - General Information)
Valve Spring Squareness (GENERAL PROCEDURES, Engine System - General Information)
Valve Spring Strength (GENERAL PROCEDURES, Engine System - General Information)
Valve Springs (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
U 3144
Valve Stem Diameter (GENERAL PROCEDURES, Engine System - General Information)
Valve Stem to Valve Guide Clearance (GENERAL PROCEDURES, Engine System - General Information)
Valve Train Components - Exploded View (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Vapor Tube Fittings (GENERAL PROCEDURES, Fuel System - General Information)
Variable Camshaft Timing (VCT) Housing (IN-VEHICLE REPAIR, Engine - 5.4L (3V))
Variable Camshaft Timing (VCT) Housing Cleaning and Inspection (GENERAL PROCEDURES, Engine
System - General Information)
Variable Camshaft Timing (VCT) Oil Control Solenoid (REMOVAL AND INSTALLATION, Electronic
Engine Controls)
Vehicle Dynamic Suspension (DESCRIPTION AND OPERATION)
Vehicle Dynamic Suspension (DIAGNOSIS AND TESTING)
Vehicle Dynamic Suspension (Section Table of Contents)
Vehicle Dynamic Suspension (SPECIFICATIONS)
Vehicle Dynamics Module (VDM) (REMOVAL AND INSTALLATION, Vehicle Dynamic Suspension)
Video Camera (REMOVAL AND INSTALLATION, Parking Aid)
Visual Inspection (DIAGNOSIS AND TESTING, Automatic Transaxle/Transmission - 6R80)
W
Warning Chimes (DESCRIPTION AND OPERATION, Instrumentation, Message Center, and Warning
Chimes)
Washer Pump (REMOVAL AND INSTALLATION, Wipers and Washers)
Washer Reservoir (REMOVAL AND INSTALLATION, Wipers and Washers)
Weld-Bonding (GENERAL PROCEDURES, Body Repairs)
Welding Precautions - Steel (DESCRIPTION AND OPERATION, Body Repairs)
Wheel Alignment Angles (DESCRIPTION AND OPERATION, Suspension System - General Information)
Wheel and Tire (DISASSEMBLY AND ASSEMBLY, Wheels and Tires)
Wheel and Tire (REMOVAL AND INSTALLATION, Wheels and Tires)
Wheel and Tire Rotation (GENERAL PROCEDURES, Wheels and Tires) >
V 3145
Wheel Bearing and Wheel Hub (REMOVAL AND INSTALLATION, Front Suspension - Four Wheel Drive
(4WD))
Wheel Bearing and Wheel Hub (REMOVAL AND INSTALLATION, Front Suspension - Rear Wheel Drive
(RWD))
Wheel Bearing and Wheel Hub (REMOVAL AND INSTALLATION, Rear Suspension)
Wheel Knuckle (REMOVAL AND INSTALLATION, Front Suspension - Four Wheel Drive (4WD))
Wheel Knuckle (REMOVAL AND INSTALLATION, Front Suspension - Rear Wheel Drive (RWD))
Wheel Knuckle (REMOVAL AND INSTALLATION, Rear Suspension)
Wheel Knuckle Bushing (REMOVAL AND INSTALLATION, Rear Suspension)
Wheel Speed Sensor - Front (REMOVAL AND INSTALLATION, Anti-Lock Brake System (ABS) and
Stability Control)
Wheel Speed Sensor - Rear (REMOVAL AND INSTALLATION, Anti-Lock Brake System (ABS) and
Stability Control)
Wheel Studs (REMOVAL AND INSTALLATION, Front Suspension - Four Wheel Drive (4WD))
Wheel Studs (REMOVAL AND INSTALLATION, Front Suspension - Rear Wheel Drive (RWD))
Wheel Studs (REMOVAL AND INSTALLATION, Rear Suspension)
Wheels And Tires (DESCRIPTION AND OPERATION, Wheels and Tires)
Wheels And Tires (DIAGNOSIS AND TESTING, Wheels and Tires)
Wheels and Tires (Section Table of Contents)
Wheels and Tires (SPECIFICATIONS)
Window Control Switch (REMOVAL AND INSTALLATION, Glass, Frames and Mechanisms)
Window Glass - Fixed, Rear Door (REMOVAL AND INSTALLATION, Glass, Frames and Mechanisms)
Window Glass - Front Door (REMOVAL AND INSTALLATION, Glass, Frames and Mechanisms)
Window Glass - Liftgate (REMOVAL AND INSTALLATION, Glass, Frames and Mechanisms)
Window Glass - Rear Door (REMOVAL AND INSTALLATION, Glass, Frames and Mechanisms)
Window Glass - Rear Quarter (REMOVAL AND INSTALLATION, Glass, Frames and Mechanisms)
Window Grid Wire Repair (GENERAL PROCEDURES, Glass, Frames and Mechanisms)
Window Motor Initialization (GENERAL PROCEDURES, Glass, Frames and Mechanisms)
Window Regulator Motor - Front Door (REMOVAL AND INSTALLATION, Glass, Frames and
Mechanisms)
W 3146
Window Regulator Motor - Rear Door (REMOVAL AND INSTALLATION, Glass, Frames and
Mechanisms)
Window Regulator Motor - Rear Quarter (REMOVAL AND INSTALLATION, Glass, Frames and
Mechanisms)
Window Regulator - Front Door (REMOVAL AND INSTALLATION, Glass, Frames and Mechanisms)
Window Regulator - Rear Door (REMOVAL AND INSTALLATION, Glass, Frames and Mechanisms)
Windshield Glass (REMOVAL AND INSTALLATION, Glass, Frames and Mechanisms)
Wiper and Washer System - Exploded View (REMOVAL AND INSTALLATION, Wipers and Washers)
Wiper Blade and Pivot Arm Adjustment - Rear (GENERAL PROCEDURES, Wipers and Washers)
Wiper Blade and Pivot Arm Adjustment - Windshield (GENERAL PROCEDURES, Wipers and Washers)
Wiper Motor - Windshield (REMOVAL AND INSTALLATION, Wipers and Washers)
Wiper Mounting Arm and Pivot Shaft - Rear (REMOVAL AND INSTALLATION, Wipers and Washers)
Wiper Mounting Arm and Pivot Shaft - Windshield (REMOVAL AND INSTALLATION, Wipers and
Washers)
Wiper Pivot Arm - Front (REMOVAL AND INSTALLATION, Wipers and Washers)
Wiper Pivot Arm - Rear (REMOVAL AND INSTALLATION, Wipers and Washers)
Wipers and Washers (DESCRIPTION AND OPERATION)
Wipers and Washers (DIAGNOSIS AND TESTING)
Wipers and Washers (Section Table of Contents)
Wipers and Washers (SPECIFICATIONS)
W 3147
SECTION 211-00: Steering System 2011 Expedition, Navigator Workshop Manual

Material

Capacity
Dye-Lite ATF/Power Steering - -
Fluid Leak Detection Dye
164-R3701 (Rotunda)
MERCON V Automatic MERCON 1.3L (2.7 pt)
Transmission Fluid V a
XT-5-QM (or XT-5-QMC) (US);

CXT-5-LM12 (Canada)
a Approximate capacity included in-pump reservoir fill.
Item Specification
Power Steering Gear
Ratio 20:1
Static steering wheel turning effort
Expedition 5.0 Nm (44 lb-in)
Navigator 4.0 Nm (35 lb-in)
Tie-rod articulation torque 5 Nm (44 lb-in)
Turning effort
Expedition 2.68 kg (5.9 lb)
Navigator 2.14 kg (4.7 lb)
Turns of steering wheel (lock to lock - linkage disconnected) 3.75
Type
Power Steering Pump
Flow (Expedition) 11L 0.8L @ 345 kPa
(3.0 gpm 0.2 gpm @ 50 psi)
engine speed @ 1,200 rpm
9.5L 0.8L @ 345 kPa
(2.6 gpm 0.2 gpm @ 50 psi)

Flow (Navigator) 11L 0.8L @ 345 kPa
(3.0 gpm 0.2 gpm @ 50 psi)
W 3148
Minimum capacity 6.6L @ 5,171 kPa
(1.6 gpm @ 750 psi)
engine speed @ 500 rpm

Relief pressure 8,963-10,204 kPa
(1,300-1,480 psi)
Power Steering Purge Vacuum
Minimum vacuum 67-84 kPa (20-25 in-Hg)
W 3149

Steering System
The power steering system consists of the following components:
Power steering pump

Power steering fluid reservoir
Steering gear
Power steering lines
Steering column
Steering column shaft
Power steering cooler (if equipped)
The power steering system transfers driver inputs at the steering wheel to the front wheels of the vehicle. The
steering column, hydraulic system and linkages that transfer these driver inputs make up the steering system.
Gearing and hydraulic assist are used to significantly reduce steering efforts.
For information on the power steering fluid reservoir, power steering pump, power steering lines and steering
gear, refer to Section 211-02 .
For information on the steering wheel, steering column and steering column shaft, refer to Section 211-04 .
Steering System 3150


Steering System
Special Tool(s)
100W/12 Volt DC UV Lamp

164-R0751
Dial Thermometer 0-220F

Evacuation Cap, Power Steering

Vacuum Pump Kit


Material
Item Specification
Dye-Lite ATF/Power Steering Fluid -
Leak Detection Dye
164-R3701 (Rotunda)
MERCON V Automatic MERCON
Transmission Fluid V
XT-5-QM (or XT-5-QMC) (US);
CXT-5-LM12 (Canada)
Power Steering
The power steering system uses a vane-type pump to move the fluid from the reservoir to the steering gear
and through the rest of the steering hydraulic system. The power steering pump is mounted to the engine and
driven by the engine accessory drive belt. Power steering fluid flows into the pump from the reservoir. The
power steering fluid is trapped between the pump vanes and moved to the high-pressure side of the pump,
creating a flow of fluid. The restriction of this flow by the steering gear creates the pressure that provides the
steering assist. A combined pressure relief/flow valve is built into the pump to control the maximum pressure
and flow provided to the steering system. This action prevents damage to the system and provides the correct
level of assist during all engine speeds. While under pressure, the power steering fluid flows through the
high-pressure power steering line to the steering gear. The fluid exits the gear and flows through the return
line, cooler and finally to the reservoir. The reservoir slows the fluid, allows air to escape and filters the fluid
before returning it to the pump.
Steering System 3151

Mechanical
Fluid level
Tire pressure
Tires
Drive belt
Drive belt tensioner (if equipped)
i>
Steering column alignment
Tie-rod ends
Suspension components
Steering column shaft U-joints
Steering column shaft bolts
Power steering reservoir screen
or filter
Pressure lines, fittings or O-rings
Power steering return hoses and
clamps
Steering gear
Power steering pump
Power steering fluid cooler (if
equipped)
3. Inspect the power steering fluid for the following conditions:

Aeration or foam: Purge the power steering system. Refer to Power Steering System Purging
in this section.
Overheating or contamination: Flush the power steering system. Refer to Power Steering
System Flushing in this section.
4. NOTE: It may be necessary to add power steering fluid to achieve the correct level.
Check the fluid level and clean the power steering components.
With the ignition OFF:
check the power steering fluid level and add fluid as necessary.
wipe off any visible signs of fluid or residue build up.
NOTICE: Do not hold the steering wheel at the stops for an extended amount of time.
Damage to the power steering pump may occur.
Start the engine and turn the steering wheel from stop-to-stop several times.
Power Steering 3152

5. Visually inspect the power steering hydraulic line/hose connections for damage or leaks.
If a leak is detected at a threaded fitting or clamp plate joint, tighten to specification. If the
leak is still evident, visually inspect the O-rings or Teflon seals. Install new O-rings or
Teflon seals as necessary. Refer to Section 211-02 .
If a leak is detected at a constant tension spring clamp, verify that the hose is not damaged
and fully installed on the hose fitting. Make sure that the constant tension spring clamp is
positioned 2 mm (0.078 in) from the end of the hose. If the leak remains, install a new
constant tension spring clamp.
If a leak is detected at a screw clamp joint, verify that the hose is not damaged and fully
installed on the hose fitting and the clamp is positioned 2 mm (0.078 in) from the end of the
hose before tightening the screw clamp. If the leak remains, install a new screw clamp. Refer
to Section 211-02 .
If a leak is detected at the Power Steering Pressure (PSP) switch, install a new switch as
necessary.
6. Visually inspect the power steering components for leaks.

If a leak detected in the pressure or return line, install a new line. Refer to Section 211-02 .
If a leak is detected in the power steering pump, install a new power steering pump. Refer to
Section 211-02 .
NOTE: On vehicles with rack-and-pinion steering gear, it may be necessary to remove the
bellows boot clamp from the steering gear bellows boot to inspect for internal steering gear
leaks.
If a leak is detected in the steering gear, repair or install a new steering gear. Refer to Section
211-02 .
If a leak is detected in the power steering reservoir, install a new reservoir. Refer to Section
211-02 .
7. For information on power steering leak detection, refer to Component Tests in this section.
proceeding.
9. If the cause is not visually evident, verify the symptom and GO to Symptom Chart - Steering System
Steering System Symptom Definitions
Drift/Pull
Pull is described as a tugging sensation felt by the hands on the steering wheel that must be overcome to keep
the vehicle going straight.
Drift describes what a vehicle with this condition does with the hands off the steering wheel.
A vehicle-related drift/pull on a flat road can cause a consistent deviation from the straight-ahead path
and require constant steering input in the opposite direction to counteract the effect.
Drift/pull can be induced by conditions external to the vehicle, such as wind or road camber.
Excessive Steering Wheel Play
Excessive steering wheel play is a condition in which there is too much steering wheel movement before the
wheels move. A small amount of steering wheel free play is considered normal.
Drift/Pull 3153
Lack of Assist or Inconsistent Assist
Lack of assist or inconsistent assist is experienced when the steering wheel effort is higher than normal. Hard
steering can remain constant through the full turn or occur near the end of a turn. It is important to know the
difference between hard steering/lack of assist and poor returnability/sticky steering.
Hard steering or lack of assist can result from either hydraulic or mechanical conditions. It is extremely
important to know if this concern occurs during driving or during high-effort parking maneuvers.
Poor Returnability/Sticky Steering
Poor returnability and sticky steering is used to describe the poor return of the steering wheel to center after a
turn or steering correction is completed.
Wander
Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to
maintain a straight path down a level road.
Symptom Chart - Steering System
Symptom Chart - Steering System
Symptom Chart - NVH
Symptom Chart - NVH

Steering system cold start noise
Blockage in the power steering fluid reservoir caused by power steering fluid contamination
NOTE: Some noise during an extremely cold start (-12.2C [-10F]) is normal and should improve as
the steering system warms up (usually within 60 seconds).
NOTE: It may be necessary to remove the power steering fluid reservoir to flush contamination
trapped in the reservoir screen.
CHECK the power steering fluid reservoir for contamination. FLUSH theer steering system as
necessary. REFER to Power Steering System Flushing in this section.
Air in the steering hydraulic system (aerated fluid)
CHECK for leaks in the system. REFER to Power Steering Leak Test Component Test in this section.
PURGE the air from the system. REFER to Power Steering System Purging in this section.
Lack of Assist or Inconsistent Assist 3154

Steering grunt or shudder - occurs when turning into or out of a turn at low speeds (temperature
sensitive)
CHECK for leaks in the system. REFER to Power Steering Leak Test Component Test. PURGE the
air from the system. REFER to Power Steering System Purging in this section.
Steering gear or power steering hoses
GO to Steeri Gear Grunt/Shudder Component Test in this section.
Steering system clonk - hydraulic knocking sound
NOTE: Some amount of clonk noise is considered acceptable. If in doubt of the acceptability,
compare to another vehicle.
CHECK for leaks in the system. REFER to Power Steering Leak Test Component Test in this section.
PURGE the air from the system. REFER to Power Steering System Purging in this section.
Power steering pump moan - loud humming noise occurs when the steering wheel is rotated to the
stop position. Produces a 120-600 Hz frequency that changes with rpm
Low fluid and/or air in the steering hydraulic system (aerated fluid)
CHECK for leaks in the system. REFER to Power Steering Fluid Leak Test Component Test. PURGE
the air from the system. REFER to Power Steering System Purging in this section. If a pump moan
still exists, INSTALL a new power steering pump. REFER to Section 211-02 .
Power steering fluid reservoir or screen is blocked or damaged
NOTE: It may be necessary to remove the power steering fluid reservoir to flush contamination
trapped in the reservoir screen.
CHECK the power steering fluid reservoir for contamination. FLUSH the power steering system as
necessary. REFER to Power Steering System Flushing in this section.
Power steering line/hose grounded to chassis
INSPECT the power steering lines/hoses. REPAIR as necessary.
Power steering pump bolts loose
TIGHTEN bolts to specification. REPAIR or INSTALL new brackets as necessary. REFER to

Section 211-02 .
Steering gear isolators
INSPECT the isolators for wear or damage. REPAIR as necessary.
Steering gear clunk - occurs only while cornering over a bump (can be temperature sensitive)
Wander 3155
Steering gear
INSPECT the steering gear for loose mounting bolts. TIGHTEN to specification as necessary.
Feedback (rattle, chuckle or knocking noise in the steering gear) - roughness is felt in the steering
wheel when the vehicle is driven over rough surfaces
Steering column shaft/U-joints damaged or worn
INSTALL a new steering column shaft. REFER to Section 211-04 .
Loose, damaged or worn tie-rod ends
INSPECT and INSTALL new tie-rod ends as necessary. GO to Steering Linkage Component Test in
this section.
Steering gear insulators or mounting bolts loose or damaged
TIGHTEN the bolts to specification or INSTALL new bolts as necessary. REFER to Section 211-02 .
Steering column shaft bolts are loose
TIGHTEN the bolts to specification. REFER to Section 211-04 .
Steering column damaged or worn
REPAIR or INSTALL a new steering column as necessary. REFER to Section 211-04 .
Power steering hiss or whistle
Steering column shaft-to-steering gear is binding or misaligned
REPAIR or INSTALL a new steering column shaft as necessary. REFER to Section 211-04 .
Grounded or loose steering column boot at the dash panel
Damaged or worn steering gear input shaft and valve
REPAIR or INSTALL a new steering gear as necessary. REFER to Section 211-02 .
Restricted power steering lines/hoses
INSTALL new power steering lines/hoses as necessary. REFER to Section 211-02 .
Steering column rattle
Loose bolts or attaching brackets
TIGHTEN the bolts to specification.
Loose, worn or insufficiently lubricated column bearings
Wander 3156
LUBRICATE bearings or INSTALL new steering column bearings or steering column as necessary.
Steering shaft insulators damaged or worn
INSTALL new insulators. REFER to Section 211-04 .
Steering column shaft compressed or extended
INSPECT the rubber spider coupling for damage. INSTALL a new steering column shaft. REFER to
Section 211-04 .
Steering gear squeak
Incorrect power steering fluid in system
If incorrect power steering fluid is suspected, FLUSH the power steering system. REFER to Power
Steering System Flushing in this section. If noise persists after system flush, INSTALL a new steering
gear. REFER to Section 211-02 .
Steering gear rotary seal
NOTE: VERIFY that the steering gear is the source of the noise. It may be necessary to replicate the
customer operating conditions (fluid temperature, turning rate of steering wheel) to get the squeak to
reoccur.
INSTALL a new steering gear as necessary. REFER to Section 211-02 .
Stone shield (if equipped)
MAKE SURE that the stone shield is correctly installed and that it is not making contact with the
steering shaft. REPOSITION stone shield or INSTALL a new stone shield as necessary.
Steering column squeak, clicks or grinds
Loose or misaligned steering column shrouds
TIGHTEN or ALIGN the steering column shrouds.
Steering wheel rubbing against steering column shrouds
REPOSITION the steering column shrouds.
Upper or lower steering column bearing
INSTALL a new steering column or steering column bearings as necessary.
Power steering pump noisy
Power steering pump
INSTALL a new power steering pump as necessary. REFER to Section 211-02 .
Power steering pump noise (steering wheel turned fully to stop/lock)
Wander 3157
Power steering fluid flow into the bypass valve of the pump valve housing, with fluid temperature
below 54C (130F)
Acceptable condition.
Power steering pump whine noise
Aerated fluid
CHECK for a leak in the system. REFER to Power Steering Fluid Leak Test Component Test in this
section. PURGE the air from the system. REFER to Power Steering System Purging in this section.

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2011 Expedition, Navigator

Master DTC Chart

Torque Wrench Adapter Formulas

00: Service Information

06: Brake System

11: Steering System

07: Automatic Transmission

08: Manual Transmission, Clutch and Transfer Case

09: Exhaust System

10: Fuel System

12: Climate Control System

14: Battery and Charging System

15: Audio Systems

18: Electrical Distribution

19: Electronic Feature Group

5: Body and Paint

02: Frame and Mounting

SECTION 100-00: Service Information 2011 Expedition, Navigator Workshop Manual

Steering Wheel Symbols

Body type symbols are used to identify different body configurations.

Gearshift lever and selector lever position symbols

Cutting Tool Symbols

Apply Chemical or load symbols

General equipment symbols

These symbols indicate the type of welding to be used.

Drilling and grinding symbols

These symbols indicate the type of drilling or grinding to be used.

1 Set the ignition switch to the 0 position

Mandatory Protective Equipment - Health and safety symbols

4 Wear ear protectors

Prohibition - Health and safety symbols and component damage

Warning Symbols - Health and Safety Warnings and Component damage

Control Diagram symbols - Description and Operation procedures

SECTION 100-00: Service Information 2011 Expedition, Navigator Workshop Manual

Using This Manual

Warnings, Notices, and Notes in This Manual

Notices provide information to avoid damage to the vehicle or a component.

Notes provide information critical for a complete and effective repair.

Vehicle and Engine Orientation Identifiers

How to Use Diagnostic Information

DTC and Symptom Charts

Using Module DTC Charts

Using This Manual 21

Mechanical Procedures Such As Removal and Installation

Reuse Of Fasteners, Seals, Or Gaskets

Seals and gaskets must be replaced unless otherwise specified.

Illustration 1 - self-locking coatings or locking feature are highlighted yellow

Illustration 1 - self-locking coatings or locking feature are highlighted yellow 22

1. Remove the engine oil pipe fastener at the engine connection.

SECTION 100-00: Service Information 2011 Expedition, Navigator Workshop Manual

General Service Health and Safety Precautions

High Voltage System Health and Safety Precautions

Climate Control System Health and Safety Precautions

Battery and Battery Charging System Health and Safety Precautions

Brake System Health and Safety Precautions

Body Repair Health and Safety and General Precautions

Engine Cooling System Health and Safety Precautions

Gasoline and Gasoline-Ethanol Fuel System Health and Safety Precautions

Diesel Fuel System Health and Safety Precautions

WARNING: Do not repair or service restraint component connector terminals. If restraint

Wheel and Tire Health and Safety Precautions

SECTION 100-00: Service Information 2011 Expedition, Navigator Workshop Manual

Effective Diagnostic Techniques

Understand and verify the symptom .